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Dixon DX254, Operator'S Manual

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Dixon DX254 Operator'S Manual Download Page 50

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Transaxle (Transmission) Fluid Change

this transaxle is designed with an external filter for 
ease of maintenance. to ensure constant fluid quality 
levels and longer life, an oil filter change interval of 
every 400 hours is recommended.
the following procedure is performed with the 
transaxles installed in the mower and the mower on 
level ground. Apply the pump release valve for each 
transaxle and set the parking brake.
1.  Remove the filter cover on the inside rear of the 

transaxle. Clean any loose debris from around the 
perimeter of the filter.

2.  Place an oil drain pan (12" or more diameter and 

8 qt. capacity is optimal) beneath the oil filter. 
Remove the oil filter from the transaxle.

Drain old oil filters of all free-flowing oil prior 
to disposal. Place used oil in appropriate 
containers and dispose of it in accordance 
with laws in your area.

3.  After the oil has drained, wipe the filter base 

surface and apply a film of new oil to the gasket of 
the replacement filter.

4.  Install the new filter by hand, turning it three-

quarters to one full turn after the filter gasket 
contacts the filter base surface.

5.  Reinstall the filter cover.
6.  Repeat steps on the opposite side.
7.  Drain old oil filters of all free flowing oil prior to 

disposal. Place used oil in appropriate containers 
and dispose of it in accordance with laws in your 
area.

8.  Remove the top fill vent port plug from the left side 

and right side of the transaxles prior to filling with 
oil. this will allow the transaxles to vent during oil 
fill.

9.  Remove the cap from the transaxles’ expansion 

tank located on the vehicle frame.

10.  Fill with 20W50 motor oil until oil just appears 

at the bottom of each transaxles’ top port 

(approximately 2 quarts per transaxle, 4 quarts 
total). Install the top port plug into each transaxle 
as the oil level reaches the port.

11.  Install and torque the top port plugs to 180 in./lbs.
12.  Continue to fill the transaxles through the 

expansion tank until the FULL COLD line is 
reached (this will take approximately 23 additional 
ounces).

13.  Reinstall the expansion tank cap by hand. Do not 

overtighten.

14.  Proceed to the purging procedure.

8050-232

1.  Filter cover
2.  O-ring
3.  Filter
4.  top fill vent port

ZT-5400 filter change

Summary of Contents for DX254

Page 1: ...or use in this machine The use of any gasoline exceeding 10 ethanol E10 will void the product warranty Please read the operator s manual carefully and make sure you understand the instructions before using the machine DX260 966651401 Form Number 115 555027 Rev A 2012 11 01 ...

Page 2: ...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 Modifications to the unit may cause unsafe operations or damage the unit When this product is worn out and no longer used it should be returned to the reseller or other party for r...

Page 3: ...TION 26 Training 26 Steering 26 Roll Bar and Safety Belt 27 Before Starting 27 Starting the Engine 28 Jumper Cables Use 31 Running 32 Operating on Hills 33 Mowing Tips 34 Stopping the Engine 35 Moving Machine By Hand 36 MAINTENANCE 37 Battery 39 Safety System 40 Fuel Filter 40 Tire Pressures 40 Parking Brake 41 Deck Belt 42 Pump Belt 43 V belts 43 Cutting Blades 44 Adjusting the Mower Deck 45 Leve...

Page 4: ...nd mind and body and must not be under the influence of any mind altering substance WARNING Engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State ...

Page 5: ...g equipment and ensure that the machine is well anchored DO NOT operate this machine on public roadways Towing If machine is equipped with a tow hitch use extreme caution when towing Never allow children or others in or on the towed equipment Make wide turns to avoid jack knifing Travel slowly and allow extra distance to stop Do not tow on sloped ground The weight of the towed equipment may cause ...

Page 6: ...manual belongs to the machine with the manufacturing number Engine Transmission The machine s manufacturing number can be found on the printed plate affixed to the right side in the engine compartment Stated on the plate from the top are The machine s type designation I D The manufacturer s type number Model The machine s serial number Serial no Please have the type designation and serial number a...

Page 7: ...o notify the reader of a risk of material damage particularly if the reader should neglect to follow instructions given in the manual Used also when there is a potential for misuse or misassembly Reverse Neutral Fast Slow Choke Fuel Warning Parking Brake CE conformity marking Only for European market Do not stand here Use protective gloves Use protective glasses IMPORTANT INFORMATION Xxxx xxxxxx x...

Page 8: ...tor s Manual Shut off engine and remove key before performing any maintenance or repair work Keep a safe distance from the machine Use on slopes no greater than 10 No passengers Whole body exposure to thrown objects Severing of fingers and toes Do not open or remove safety shields while engine is running Careful backing up watch for other people Careful going forward watch for other people ...

Page 9: ...ns to operate the machine Clear the area of objects such as rocks toys wire etc which could be picked up and thrown by the blades Be sure the area is clear of bystanders before operating Stop machine if anyone enters the area Never carry passengers The machine is only intended for use by one person Do not mow in reverse unless absolutely necessary Always look down and behind before and while backi...

Page 10: ...tion when operating machine Wear proper Personal Protective Equipment PPE while operating this machine including at a minimum sturdy footwear eye protection and hearing protection Do not mow in shorts and or footwear with open toes Data indicates that operators age 60 years and above are involved in a large percentage of riding mower related injuries These operators should evaluate their ability t...

Page 11: ... the machine Tall grass can hide obstacles Choose a low ground speed so that you will not have to stop while on the slope Do not mow on wet grass Tires may lose traction Avoid starting stopping or turning on a slope If the tires lose traction disengage the blades and proceed slowly straight down the slope Keep movement on the slopes slow and gradual Do not make sudden changes in speed or direction...

Page 12: ...tivity Never assume that children will remain where you last saw them Keep children out of the mowing area and in the watchful care of a responsible adult other than the operator Be alert and turn machine off if a child enters the area Before and while backing look behind and down for small children Never carry children even with the blades shut off They may fall off and be seriously injured or in...

Page 13: ...e a vehicle or on a truck or trailer bed with plastic liner Always place containers on the ground away from the vehicle when filling Remove gas powered equipment from the truck or trailer and refuel it on the ground If this is not possible refuel such equipment with a portable container rather than from a gasoline dispenser nozzle Keep the nozzle in contact with the rim of the fuel tank or contain...

Page 14: ...rp Wrap the blade or wear gloves and use extra caution when servicing them Check brake operation frequently Adjust and service as required Maintain or replace safety and instruction labels as necessary Do not modify safety equipment Check regularly to be sure it works properly The machine must not be driven with defective or unmounted protective plates protective cowlings safety switches or other ...

Page 15: ...mes contain carbon monoxide an odorless poisonous and lethal gas Stop to 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 a...

Page 16: ...loss of traction and loss of control Follow the manufacturer s recommendation for weight limits for towed equipment Do not tow near ditches canals and other hazards Spark Arrestor A spark arrestor for the muffler is available through any authorized Husqvarna dealer IMPORTANT INFORMATION The parking brake is not sufficient to lock the machine in place during transport Ensure that the machine is wel...

Page 17: ...opes too steep for safe operation Watch where you are going especially at row ends on roads and around trees Do not permit others to ride Operate the mower smoothly no jerky turns starts or stops When mower is stopped set brakes securely and use park brake If any part of ROPS is damaged the entire ROPS must be replaced Check all bolts including seat belt for correct torque before each use Check RO...

Page 18: ...iven hydraulic pumps Using the left and right steering controls the flow is regulated and thereby the direction and speed Control Locations 1 2 3 4 5 6 8 9 10 12 7 1 Motion control levers 2 Tracking bolt left side 3 Parking brake 4 Fuel tank left 5 Pump release valves 6 Hour meter 7 Ignition switch 8 Choke control 9 Throttle control 10 Blade switch 11 Deck lift 12 Deck release 11 ...

Page 19: ...is reduced and the machine turns to the right Zero turn can be achieved by moving one control backward behind the neutral position and carefully moving the other steering control forward from its neutral position The rotation direction when zero turning is determined by which steering control is moved backward behind the neutral position If the left steering control is pulled backward the machine ...

Page 20: ...ke Always set the parking brake before dismounting Release the parking brake before moving the mower 8065 006 Parking brake 8050 601 Throttle control Throttle Control The throttle control regulates the engine speed and the rate of rotation of the blades assuming the blade switch is pulled out To increase or decrease the engine speed the control is moved forward or back respectively Avoid idling th...

Page 21: ...er to provide the engine with a richer fuel mixture For cold starts the control should be pulled up Hour Meter The hour meter displays the total operating time with the blade activated The display on the hour meter will turn on the oil can icon after every fifty hours of use and will stay on for two hours or until the meter is manually reset To manually reset the timer turn the ignition key to the...

Page 22: ...ut 4 Test operate the unit by driving it at full throttle and the full forward position on both motion control levers Gradually turn in the right hand tracking bolt until the unit noticeably starts drifting right 5 Drive forward at full throttle with both motion control levers in the full forward position Gradually turn in the left tracking bolt until unit tracks straight 8065 060 Tracking adjustm...

Page 23: ...pedal fully forward until the deck lift latches in the transport highest position 8065 017 1 Lift pedal 2 Release pedal Cut height selection pedals Seat Adjustment Lever The seat can be adjusted lengthways The lever is located at the right side of the seat as seen by the driver in the seat When making adjustments the lever is moved to the left or upward depending on model 8065 088 Seat adjustment ...

Page 24: ...ar of the seat The valve is off when the handle tab is turned perpendicular to the fuel line Hydro Bypass Transaxle bypass must be engaged when pushing or pulling the mower The bypass valves are located on the inner front sides of the transaxles See Moving Machine By Hand in the Operation section 8050 233 Hydro bypass right side ...

Page 25: ...operation Risk for burns if touched Allow engine and exhaust system to cool before refueling WARNING Fill to bottom of filler neck Do not overfill Wipe off any spilled oil or fuel Do not store spill or use gasoline near an open flame 8065 007 Gasoline fuel tanks IMPORTANT INFORMATION It is recommended that fuel be added to both tanks on initial start up Read the safety instructions before refuelin...

Page 26: ... To move unit under its own power the operator must be in the seat start engine see Before Starting in the Operation section adjust engine speed to idle disengage parking brake do not engage blades at this time rotate control levers inward As long as the control levers have not been moved forward or backwards mower will not move Slowly move both control levers forward slightly This will allow mowe...

Page 27: ...he 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 8065 011 Roll bar in upright position WARNING The seat belt must be used when the roll bar is in upright position 8065 006 Activate parking brake before starting 8...

Page 28: ...ort position Set the pin at the desired cutting height Height selection pin is removed by rotating 180O Make sure that the pin is reinserted fully through the both sides of the height panels The following conditions must be fulfilled before the engine can be started The blade switch for engaging the mower blades must be depressed The parking brake must be on Both steering controls must be in the l...

Page 29: ...d outer neutral position 7 Open the fuel tank valve 6 Move the throttle to the middle position If the engine is cold the choke control should be pulled up 8065 108 Place controls in neutral position 8050 605 Set the throttle and choke 8065 098 Fuel tank valve OPEN ...

Page 30: ... at a moderate speed approximately mid throttle for 3 5 minutes before loading it too heavily USE FULL THROTTLE WHEN MOWING no choke 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 Do not use the machin...

Page 31: ...OUND on the mower with the discharged battery away from the fuel tank and battery To remove cables reverse order 4 Remove BLACK cable first from chassis and then from the fully charged battery 5 Remove RED cable last from both batteries 8011 642 Jumper cable connection IMPORTANT INFORMATION The mower is equipped with a 12 volt negative grounded system The other vehicle must also be a 12 volt negat...

Page 32: ...al position N 3 Release deck height control by applying equal pressure to both pedals Push pedals again to lower deck to selected setting 4 Move throttle control to full throttle 5 Engage the mower deck by pulling out the blade switch 8065 006 Release the parking brake 8065 119 Set deck to selected cutting height WARNING Make sure that no one is near mower when engaging blade switch Make sure the ...

Page 33: ...006 Release the parking brake The slowest speed possible should be used before starting up or down hills Avoid stopping or changing speed on hills If stopping is absolutely necessary pull drive levers into the neutral position and push to the outside of the unit and engage the parking brake To restart movement release the parking brake Pull the control levers back to the center of the mower and pr...

Page 34: ... The lawn becomes more even and the grass clippings more evenly distributed over the mown area The total time taken is not increased as a higher operating speed can be used without poor mowing results Avoid mowing wet lawns The mowing result is poorer because the wheels sink into the soft lawn clumps build and the grass clippings fasten under the cowling Hose the mower deck underside with water af...

Page 35: ...ding still activate the parking brake by pulling the lever upward 6 Turn the ignition key to the stop position If the engine has been worked hard allow it to idle a minute in order to attain a normal operating temperature before stopping To prevent fouling the spark plugs avoid idling the engine for longer periods 7 Remove key To prevent unauthorized use always remove key when leaving the mower 80...

Page 36: ...ng the mower engage the bypass valve on each transaxle Access to the valves is from the lower rear of the unit The bypass valves are located on the front inner sides of the transaxles Set the deck to the lowest position when accessing the pump valves To disengage each pump turn the slot on the pump valve 45O clockwise from the RUN position to the BYPASS position 8050 231 Right side ZT 5400 valve ...

Page 37: ...arking brake Check the engine s oil level every refueling Check the safety system Check for fuel and oil leakages Check clean the engine s cooling air intake Check the mower deck Check for loose hardware screws nuts Clean under the mower deck Start the engine and blades listen for unusual sounds Check for damage Thoroughly clean around the engine Clean around belts belt pulleys Check the tire pres...

Page 38: ... the engine oil filter Clean replace the spark plugs Replace the fuel filter Replace the paper air filter 2 Check the caster wheels every 200 hours Replace the air cleaner s foam pre filter 2 Check the hydraulic oil in the oil tank Change the hydraulic oil every 500 hours Replace the hydraulic oil filter every 500 hours Dismantle and inspect starter 3 every 500 hours Check adjust the mower deck Ch...

Page 39: ... CHARGE 12 4V 75 20 min 35 min 48 min 90 min 12 2V 50 45 min 75 min 95 min 180 min 12 0V 25 65 min 115 min 145 min 280 min 11 8V 0 85 min 150 min 195 min 370 min Charging time depends on battery capacity condition age temperature and efficiency of charger Battery Removal Corrosion and dirt on the battery and terminals can cause the battery to lose power 1 Lift the seat and rotate fully forward unt...

Page 40: ...ves off the driver s seat IMPORTANT INFORMATION To be able to drive the driver must sit in the seat and release the parking brake before the steering controls can be moved into the neutral position otherwise the engine will stop 8065 021 Conditions for starting Fuel Filter Replace the line mounted fuel filter every 100 hours once per season or more often if it becomes clogged 1 Move the hose clamp...

Page 41: ...onging to the parking brake Perform a standstill test and check that there is sufficient braking action IMPORTANT INFORMATION The machine must be standing still when applying the parking brake 8065 006 Parking brake WARNING Faulty adjustment result in reduced braking ability and can cause an accident ...

Page 42: ...leys 5 Remove the belt guide hardware with a wrench and set belt guide aside 6 Remove the belt from around the electric clutch on the engine shaft 8065 046 Remove belt guide Deck Belt Installation NOTE For ease in installing the deck belt refer to the routing decal on the cutting deck 1 Place the belt around all the pulleys except the center spindle pulley 2 With a breaker bar shift the idler arm ...

Page 43: ...e of the idler pulley 4 With a breaker bar and using the square opening in the idler arm shift the arm to create slack in the belt While holding the idler back with the breaker bar wrap the belt around the right pump pulley 5 Replace and secure clutch stop 6 Reinstall the deck belt See Deck Belt Installation in this section of the manual 8065 092 1 Electric clutch 2 Idler release placement 3 Clutc...

Page 44: ...ening Check the blade mounts Blade Replacement 1 Remove blade bolt by turning counterclockwise 2 Install new or re sharpened blade with stamped GRASS SIDE facing towards ground grass down or THIS SIDE UP facing deck and cutter housing 3 Install and tighten blade bolt securely 4 Torque blade bolt to 90 ft lbs 122 Nm IMPORTANT INFORMATION Special blade bolt is heat treated Replace with a Dixon bolt ...

Page 45: ...ement Move to the opposite side check that measurement is the same If adjustment is required loosen the locknut and adjust bolt up until both side to side measurements are equal Retain measurement 3 Turn both outer blades to align with the deck in front to rear manner Reposition rear mounting bolts up or down until rear blade tips are positioned 1 8 to 3 8 higher in the rear than the front blade t...

Page 46: ...ower position 4 to 5 102 to 127 mm grass 8065 030 1 Caster bolt 2 Axle spacer Caster wheel Caster Wheels Check every 200 hours Check that wheels rotate freely Removal and Installation Remove nut and caster bolt Pull the wheel out of the fork Install in reverse order Tighten caster bolt Torque to 45 ft lbs 61 Nm then back nut off turn NOTE Tire should rotate freely but axle spacers should not If wh...

Page 47: ...or approval before conducting maintenance of a Hydro Gear product unless the servicing dealer is a current Authorized Hydro Gear Service Center Regular external maintenance of the ZT 5400 Powertrain should include the following 1 Check oil level in expansion tanks When the engine is cold the tanks should be at the FULL COLD level 2 Inspect the vehicle drive belt idler pulley s and idler spring s I...

Page 48: ...e unless otherwise stated use high grade molybdenum disulphide grease For daily use the machine should be lubricated twice weekly Wipe away excess grease after lubrication It is important to avoid getting lubricant on the belts or the drive surfaces on the belt pulleys Should this happen attempt to clean them with spirits If the belt continues to slip after cleaning it must be replaced Gasoline or...

Page 49: ...xpose zerk Lubricate with a grease gun until the grease is forced out around the top washer Front Wheel Bearings Lubricate 3 4 strokes with a grease gun on each set of wheel bearings 8065 032 Lubricating front wheels 8050 131 Deck spindle Deck Spindle Lower the cutting deck completely If a grease gun without rubber hose is used the foot plate must be removed Lubricate with a grease gun 2 3 strokes...

Page 50: ...w filter by hand turning it three quarters to one full turn after the filter gasket contacts the filter base surface 5 Reinstall the filter cover 6 Repeat steps on the opposite side 7 Drain old oil filters of all free flowing oil prior to disposal Place used oil in appropriate containers and dispose of it in accordance with laws in your area 8 Remove the top fill vent port plug from the left side ...

Page 51: ...mal operating conditions See Moving Machine By Hand in the Operation section for bypass linkage adjustments 1 Disengage the brake if activated 2 With the bypass linkage open and the engine running at fast idle slowly move the directional control in both forward and reverse directions 5 or 6 times As air is purged from the unit the oil level will drop 3 With the bypass linkage closed and the engine...

Page 52: ...or contact of the battery terminal cable connections Blown fuse Fault in the starter safety circuit See Safety System in the Maintenance Section Engine runs rough Faulty carburetor Choke control is pulled out with a warm engine Clogged fuel filter or jet Clogged ventilation valve on the fuel cap Fuel tank nearly empty Fouled spark plugs Rich fuel mixture or fuel air mixture Wrong fuel type Water i...

Page 53: ... brake on Bypass valve on pump open Drive belt for the transmission slack or has come off Air trapped in hydraulic system Mower deck not engaging Drive belt for the mower deck has come loose Contact for the electromagnetic coupling has loosened Blade switch is faulty or has come loose from cable contact Blown fuse Transaxle leaks oil Damaged seals housing or gaskets Air trapped in hydraulic system...

Page 54: ... 4 Empty the fuel tanks or add a fuel stabilizer Start the engine and allow it to run until the carburetor is drained of fuel or the stabilizer has reached the carburetor 5 Remove the spark plug and pour about a tablespoon of engine oil into the cylinder Turn over the engine so that the oil is evenly distributed and then refit the spark plug 6 Lubricate all grease zerks joints and axles 7 Remove t...

Page 55: ...WIRING DIAGRAM 55 TIMER SCHEMATIC ...

Page 56: ...mph 0 19 3 Km h Speed reverse 0 6 mph 0 9 7 Km h Brakes Internal Cog Front caster tires smooth tread 13 x 6 5 6 Rear tires turf pneumatic 24 x 12 12 Tire pressures 15 PSI 103 kPa 1 bar 1 See the Engine Manufacturer s manual for engine specifications 2 The power rating of the engines indicated is the average net power output at specified rpm of a typical production engine for the engine model measu...

Page 57: ...ble Seat Suspension Hinged Arm Rests Yes Hour Meter Yes Blade Engagement 150 ft lb Ogura Deck Construction 7 gauge Productivity 5 8 acres h 2 3472 m2 h Dimension Weight 1320 lbs 599 kg Base Machine Length 82 210 cm Base Machine Height 47 121 cm Base Machine Width 55 140 cm Overall Width Chute Up 61 156 cm Overall Width Chute Down 73 185 cm Overall Height ROPS Up 72 183 cm ...

Page 58: ... or coarse thread 9 12 13 18 5 16 18 24 28 38 24 33 3 8 31 42 46 62 40 54 7 16 50 68 75 108 75 102 115 156 9 16 110 150 165 224 5 8 150 203 225 305 250 339 370 502 7 8 378 513 591 801 11 8 782 1060 1410 1912 Grade 5 Minimum commercial quality lower quality not recommended Metric Standard Hardware Grade Grade 8 8 Grade 10 9 Grade 12 9 Size ft lbs Nm ft lbs Nm ft lbs Nm Shank Size Diameter in inches...

Page 59: ...t 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 Take care of them as they are valuable documents ...

Page 60: ...justment Check Safety switch for the parking brake Safety switch for the mower deck Safety switch in the seat Safety switch in the steering controls Parking brake functionality and adjustment Driving forward Driving backward Engaging the blades Check the idle speed Check the engine high idle speed Inform the customer about The need and advantages of following the service schedule The need and adva...

Page 61: ...gine 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 ROPS Check fuel system for leaks Inspect safety guards and shields Check brake adjustment ...

Page 62: ...s from mower Check engine oil level Check the tire pressures Check underside of deck Inspect deck pulleys Check clean the engine s cooling air intake Check safety system Check seat belt Check ROPS Check fuel system for leaks Inspect safety guards and shields Check brake adjustment ...

Page 63: ...is from mower Check engine oil level Check the tire pressures Check underside of deck Inspect deck pulleys Check clean the engine s cooling air intake Check safety system Check seat belt Check ROPS Check fuel system for leaks Inspect safety guards and shields Check brake adjustment ...

Page 64: ... Inspect fuel filter Check engine RPM Clean underside of deck Check blade pitch Grease blade spindles Inspect spindle bearings Inspect deck belt and blades Inspect idler arm bearings Inspect deck idler pulleys Check hydraulic oil level Inspect hydraulic filter Inspect hydraulic drive belt Inspect hydraulic hoses Check neutral position Inspect battery connections Check safety system Check seat belt...

Page 65: ... RPM Clean underside of deck Check blade pitch Grease blade spindles Inspect spindle bearings Inspect deck belt and blades Inspect idler arm bearings Inspect deck idler pulleys Change hydraulic oil level Change hydraulic filter Replace hydraulic drive belt Inspect hydraulic hoses Check neutral position Inspect battery connections Load test battery Clean electrical connections Inspect the clutch Ch...

Page 66: ...ke Replace the air cleaner s foam pre filter Replace the air filter s paper cartridge Change the engine oil Replace the engine oil filter Check adjust the cutting height Check adjust the parking brake Clean Change the spark plugs Inspect spark plug Check the engine valve clearance Check the engine valve clearance ...

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