Dixon ZTR manual

Safety Instructions & Operator ’ s Manual KODIAK ™ DIESEL ZTR ®[...]

2 IMPOR T ANT - READ CAREFULL Y The Dixon® ZTR® mower is both easy and fun to operate. However , any power mower must be operated properly to be safe. It is not a toy or a recreational vehicle. Before you start to use the mower , read this Operator ’ s Manual carefully . It contains valuable information that is necessary for the safe operation [...]

3 T ABLE OF CONTENTS Page SAFETY & W ARNING ....................................4-15 W ARRANTY ........................................................16 SPECIFICA TIONS.............................................17 SEA T ADJUSTMENT .........................................18 CONTROLS.................................................. 19-21 OPE[...]

SAFETY 4 Blade Contact Tip Over Run Over Back Over RIDING LA WN MOWERS, IF IMPROPERL Y OPERA TED CAN CAUSE SERIOUS INJURY OR DEA TH Pictured below are the most common causes of injury to the operator or bystander . Please read and understand this manual to prevent injuries.[...]

SAFETY 5 Safety Alert Symbol When you see this symbol, BE ALERT to the potential for injury . Follow the recommended safety precautions and safe operating practices. DANGER (highlighted in red) indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury . WARNING (highlighted in orange) indicates a pote[...]

W ARNING 6 Failure to observe the following safety instructions could result in serious injury or death. GENERAL OPERA TION: Read, understand, and follow all instructions in this manual and on the mower before starting. Only allow responsible adults, who are familiar with the instructions, to operate the mower . Clear the area of objects such as ro[...]

W ARNING 7 GENERAL OPERA TION (continued): Never leave a running mower unattended. Always turn off blades, set parking brake, stop engine and remove key before dismounting. T urn off blades when not mowing. Injury could occur from contact with moving parts. Under no circumstances should you place hands or feet under the mower deck or in the chute w[...]

W ARNING 8 Never dismount mower without applying parking brake or stopping engine. Protect your eyes. Always wear safety goggles or safety glasses with side shields when operating mower . 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[...]

W ARNING 9 SLOPE OPERA TION: Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes require extra caution. If you feel uneasy on a slope, do not mow it! DO Mow across the slope with your Dixon® ZTR® -- never up or down. This will decrease the risk of tip-over . Remove ob[...]

W ARNING 10 Keep all movement on the slopes slow and gradual. Do not make sudden changes in speed or direction. Use extreme caution when operating the mower with attachment s to prevent tip-over or roll-over . If front wheels lift off the ground, pull levers back to stabilize the mower . Discontinue mowing the slope! When operating on slopes over 1[...]

W ARNING 11 SLOPE OPERA TION (continued): DO NOT Do not turn on slopes unless necessary , and then, turn slowly and gradually downhill, if possible. Rapid uphill turns may cause tip-over . Do not mow near drop-offs, ditches, or embank- ments. The mower could suddenly turn over if a wheel is over the edge of a cliff or ditch or if an edge caves in. [...]

W ARNING 12 FIRE HAZARDS: Use extra care when handling diesel and other fuels. They are flammable and vapors are explosive. Store all fuel in approved containers specifically designed for that purpose. Allow engine to cool before refueling. Never remove fuel cap or add fuel with engine running. Do not smoke while refueling or operating the mower . [...]

W ARNING 13 FIRE HAZARDS (continued): T o prevent fire or explosion, keep sp arks and open flames away from battery . Keep electrical connections clean and tight. Inspect them often. Loose connections and corrosion increase fire risk. Before disconnecting the negative ground cable, make sure all switches are off. This decreases the chance of sparki[...]

W ARNING 14 CHILDREN: Tragic accidents can occur if the operator is not alert to the presence of children. Children are attracted to lawn mowers and the mowing activity . NEVER assume children will stay where they were last seen. Be alert to avoid accidents. Keep children out of the mowing area and under the watchful care of another responsible adu[...]

W ARNING 15 SERVICE: Never run a mower inside a closed area or without proper ventilation. Keep nuts and bolts tight, especially blade attachment bolts, and keep equipment in good condition. Never tamper with safety devices. Check their proper operation regularly . Stop and inspect the equipment if you strike an object. Repair , if necessary , befo[...]

16 DIXON® ZTR® PRO SERIES COMMERCIAL/RESIDENTIAL W ARRANTY POLICY Black Bear TM , Kodiak™, Grizzly™ & SilverTip™ Mowers DIXON® WARRANTS ITS ZTR® MOWERS AGAINST DEFECTS IN MATERIAL AND WORKMANSHIP FOR THE PERIODS SET FORTH BELOW. THE SOLE REMEDY UNDER THIS WARRANTY IS REPLACEMENT OR REP AIR OF P ARTS INCLUDING LABOR COSTS. THIS W ARRAN[...]

SPECIFICA TIONS 17 SPECIFICA TIONS SUBJECT TO CHANGE WITHOUT NOTICE Additional information may be provided elsewhere in this manual. KODIAK™ DIESEL CHASSIS: 1 1 G A - rectangular tube S E A T : Designed for operator comfort by use of high-density closed cell foam padded back and arm rests, upholstered with Cordura TM water-repellent fabric. Seat [...]

18 SEA T ADJUSTMENT INSTRUCTIONS 1 . Grasp seat slide adjuster and move it into adjustment position. 2 . Slide seat forward or backward. 3 . Release seat slide adjuster .[...]

CONTROLS 19 CONTROL LEVERS Note: For access to the seat, move control levers to neutral position and swing them outward. T O GO FOR W ARD •From neutral position, gently push control levers for- ward. •T o increase speed, move levers further forward. T O GO BACKW ARDS •From neutral position, gently pull control levers toward you. TURNING •T [...]

CONTROLS 20 CAUTION MOWER DECK CUT HEIGHT LIFT LEVER: • Located to the right and front of the operator . • Controls the cutting height. • Eighteen positions of adjustment • Push foot lever forward, depress trigger and move lever forward to lower deck. • Push foot lever forward, depress trigger and pull lever back to raise deck. Note: Alwa[...]

CONTROLS 21 BLADE DRIVE: •Located on the control panel, on operator ’s right. •T o engage the mower blade, pull up on the switch. •T o disengage mower blade, push down. CIRCUIT BREAKER: •Located on the control panel to the operator ’s right. •Protection of the electrical system is by (1) 15 amp circuit breaker . •If circuit breaker [...]

OPERA TION INSTRUCTIONS 22 The safe and successful operation of the KODIAK™ Diesel will depend upon the operator having the correct knowledge of all controls used on the mower and making good judgements about the terrain to be mowed. NEVER allow anyone to operate the mower without complete knowledge of all controls and their functions. NEVER dism[...]

OPERA TION INSTRUCTIONS 23 CAUTION Failure to follow these instructions may result in personal injury . ST ARTING INSTRUCTIONS: 1. Parking brake must be on, control levers in outward position and blade drive disengaged. 2. Position throttle to 1/2 speed setting. 3. Insert ignition key and turn to “run” position. Allow glow plugs to cycle for up[...]

OPERA TION INSTRUCTIONS 24 P ARKING BRAKE SWITCH TEST : a) Swing control levers to outward position b) Disengage blade drive switch c ) Put parking brake in OFF position d) T urn ignition switch to ST ART Engine should not turn over or attempt to start. CONTROL LEVER SWITCH TEST : a) Disengage blade drive switch b) Put parking brake in ON position [...]

OPERA TION INSTRUCTIONS 25 TESTING OF SAFETY INTERLOCK SYSTEMS: BLADE DRIVE SWITCH TEST : a) Put parking brake in ON position. b) Swing control levers to outward position. c ) Engage blade drive switch. d) T urn ignition switch to ST ART . Engine should not turn over or attempt to start. SEA T SWITCH TEST : a) In a SAFE AREA away from bystanders, s[...]

OPERA TION INSTRUCTIONS 26 MOWING WITH A MULCHING A TT ACHMENT : Mulching or recycling the grass clippings requires a totally different mowing approach than would be normal when side discharging or bagging the grass. There may be instances or conditions where it is not possible to hide all the recycled or mulched clippings. In order to achieve the [...]

OPERA TION INSTRUCTIONS 27 MOWING WITH A MULCHING A TT ACHMENT (continued): 7. Keep the underside of the mower deck clean. Remove all grass and dirt build-up from the underside of the pan, the baffles and deflectors after each use. Never , under any circumstances, should you place hands or feet under the mower deck or in the chute while blades or i[...]

OPERA TION INSTRUCTIONS 28 MOWING WITH A GRASS CA TCHER A TT ACHMENT : In order to achieve optimum performance when mowing with a grass catching attachment, please read and follow the tips listed below . 1. Read and follow the installation instructions that are included with your grass catcher . 2 . Set engine speed control to the wide open or full[...]

OPERA TION INSTRUCTIONS 29 MOWING WITH A GRASS CA TCHER A TT ACHMENT (continued): 8 . Some mowing applications/use of grass catchers may require that an additional weight kit be fitted to the mower to counter the weight of grass in the bags. Please consult with your dealer for more information regarding installation and adding weight to the box. 9 [...]

OPERA TION INSTRUCTIONS 30 SIDE DISCHARGE OF THE CLIPPINGS: In order to achieve optimum performance when side discharging the grass clippings, please read and follow the tips listed below . Additional information can be found in the T roubleshooting guide. CAUTION T o avoid personal injury , be sure that the deflector is properly installed on the d[...]

OPERA TION INSTRUCTIONS 31 GRASS HEIGHT & CUTTING SUGGESTIONS: Do not attempt to cut grass when it is wet. If the grass is tall, place the mower deck cut height lever in the top or second notch. “Initially” overlap cutting swaths instead of a full swath with each pass. Some applications may require a second cutting. Keep the underside of th[...]

OPERA TION INSTRUCTIONS 32 TOWING TRAILERS AND OTHER ATTACHMENTS: T owing a trailer or other attachment that is too heavy could damage the drive or cause the mower to become unstable. Limit loads to 500 pounds or less with this mower . TO FREE WHEEL MACHINE (Unlock Transmission): Always turn off engine before engaging or disengaging the hydro relea[...]

CARE AND MAINTENANCE 33 W ARNING Failure to observe the following instructions may result in personal injury . Before performing any maintenance, turn off engine, allow to cool & remove key . Use extreme care when working on machinery . Do not wear watch or jewelry . Do not wear loose fitting clothes, and observe all common safety practices wit[...]

CARE AND MAINTENANCE 34 CUTTER BLADE MAINTENANCE: CAUTION Stop engine and remove ignition key for safety . Wear heavy , thick gloves when holding onto cutter blade, avoid the sharp edge of the blade. Blades should be discarded when worn excessiv ely . DANGEROUS! DO NOT USE BLADE IN THIS CONDITION! When notch starts, discard blade New Blade Check sh[...]

CARE AND MAINTENANCE 35 ENGINE: For complete maintenance and operating information of the engine, please refer to the maintenance instructions furnished by the engine manufacturer included in your Zero T urn Radius mower information packet. BA TTER Y : This is a maintenance-free battery and the fluid level cannot be checked. •Charge battery if re[...]

CARE AND MAINTENANCE 36 TIRES: Correct tire pressure is essential for efficient operation of the mower . Check tire pressure periodically . Inflate tires to the pressure listed below . Front tires 13 x 6.50 - 6 16-21 lbs. Rear tires 23 x 10.0 - 10 8-14 lbs. Lug nuts or lug bolts should be checked regularly for tightness. LUBRICA TION: CHASSIS: (1 1[...]

CARE AND MAINTENANCE 37 BEL TS: Check belts every 50 hours. Replace any belts found to be in poor condition. BEL T TENSION: Engine to Mower Deck Belt: P/N 1 1339 T o adjust tension of the mower deck drive belt, turn adjuster nut on threaded eyebolt. T urning nut to the right will make the belt tighter . T urning nut to the left will loosen the belt[...]

CARE AND MAINTENANCE 38 CAUTION HOT oil may cause burns. Allow engine to cool before draining oil. Hex Head Valve Stem CHANGING THE ENGINE OIL: 1 . The “Dapco” oil drain valve is located on either side of the engine crankcase (depending on the type of engine installed on your ZTR®). 2. Place a suitable container under the drain valve hose. 3. [...]

CARE AND MAINTENANCE 39 HOT oil may cause burns. Allow engine to cool before draining oil. OIL FILL: 1 . Clean any spilled oil from engine and chassis. 2. Refill engine with type, and quantity of oil recom- mended by the engine manufacturer in engine literature. NOTE: Engine oil changes on the KODIAK™ will require replacement of the oil filter . [...]

CARE AND MAINTENANCE 40 HYDROST A TIC TRANSMISSION FLUID & FIL TER SERVICE: Dirt or water in fluid can ruin the hydrostatic transmissions. SER VICE INTER V ALS: 1. Initial filter service - 100 hours 2. Every 500 hours or once a year thereafter . RECOMMENDED FLUID: All temperatures - Dixon Blue™ 15W-50 Synthetic Hydrostatic Fluid ~or if not av[...]

CARE AND MAINTENANCE 41 HYDROST A T FLUID MAINTENANCE PROCEDURE: Check the fluid level in hydrostatic transmisison fluid reservoir after every 25 hours of usage. Clean the fluid reservoir cap and the area around it prior to removal. Check the fluid level. Fluid should be approximately 1/4” below top of fluid tank baffle. Replenish as needed with [...]

CARE AND MAINTENANCE 42 NEUTRAL ADJUSTMENT 1 . Lift seat. 2. Block up the unit so that the drive wheels are off the ground. 3 . Loosen ball joint jam nuts on control rod. Note: The front jam nuts are left hand threads. 4 . With steering control arms in the “out” neutral position, start the engine and run at fast idle. 5. Adjust the neutral posi[...]

CARE AND MAINTENANCE 43 NEUTRAL SPRING ADJUSTMENT : 1 . Loosen set screws on center spring stop collar located on the control rods. (Requires a 1/8” Allen wrench). 2. Swing control lever out. T ighten set screw on lock collar . 3 . Repeat for opposite side. 4 . Engage parking brake and lower seat frame. Release parking brake and swing control lev[...]

CARE AND MAINTENANCE 44 LEVELING THE DECK: 1. Set the tire pressure on all four tires. 2. Move the mower to a hard, level surface and rotate front casters in the direction of forward travel. 3. Put the mower deck in the mid-range cut height position. 4. Rotate the 2 outer blades so the blade tips point outboard. 5. T urn front adjuster nut(s) to le[...]

CARE AND MAINTENANCE 45 MOWER DECK REMOV AL: 1. Remove hardware which connects the two deck trail arms to the rear of the mower deck. Rear of deck trail arms remain attached to mower frame. 2. Remove deck drive belt. 3. Remove hardware connecting rear hangers to mower deck (2 places). 4. Remove hardware connecting front hangers to mower deck (2 pla[...]

CARE AND MAINTENANCE 46 ELECTRICAL SYSTEMS: Keep all connections clean and tight. CLEANING THE MOWER: W ash mower periodically . Clean above and below deck. High pressure washing and alkaline based soaps can cause damage to bearings and other parts of the mower . After washing your mower , start the engine and engage the mower deck for a few minute[...]

47 1. ENGINE WON’T TURN OVER Mower blades engaged- - - - - - - - - - - - - - - - - - - disengage blades Parking brake not on- - - - - - - - - - - - - - - - - - engage parking brake Circuit breaker trips- - - - - - - - - - - - - - - - - - - - - - - - -reset breaker Dead battery- - - - - - - - - - - - - - - - - - - - - - - - - - charge or replace S[...]

48 TROUBLESHOOTING 6. ENGINE RUNS BUT MOWER WON’T MOVE FORWARD Drive belt broken or slipping- - - - - - - - - - - - - - - - replace drive belt T ransmission oil low- - - - - - - - - - - - - - - - - - - - - - - - - - - - add oil Damaged transmission- - - - - - - - - - - - - - - - - - - - - -consult dealer T ransmission by-pass may be engaged- - - [...]

49 ENGINE AIR AND OIL FIL TERS Refer to Engine Operator ’ s Manual for correct service intervals for engine oil changes and air filter maintenance. Protect your engine investment, use only original equipment filters. Refer to the Engine Operator ’s Manual or ask your dealer for correct replacement parts. ST ANDARD SERVICE P ARTS LIST Blades *Hi[...]

50 NOTES[...]

OWNER’S INFORMA TION Date of Purchase Mower Model Number Mower Serial Number Purchased From Name Address DA TE OIL CHANGED DA TE ENGINE TUNED Dixon Industries, Inc.~P .O. Box 1569~Coffeyville, Ks~620-251-2000~Fax 620-251-41 17[...]

Dixon® and ZTR® are registered trademarks of Dixon Industries, Inc. DIXON INDUSTRIES, INC. P .O. Box 1569 Coffeyville, Ks 67337-0945 620-251-2000 KODIAK™ Part No. 18626-1005 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. WARNING :[...]