Dixon ZTR44/968999690 manual

BLACK BEAR ™ ZTR ® BLACK BEAR ™ ZTR ®[...]

WARNING! Failure to follow cautious operating practices can result in serious injury to the operator or other person. The owner must 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. WARNING! Engine exhaust, some of i[...]

CONTENTS Introduction ................................................ 4 Congratulations ..................................... 4 Use ........................................................ 4 Good service ......................................... 5 Serial number ........................................ 5 Symbols and decals .........................[...]

English - 4 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 [...]

English - 5 INTRODUCTION 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. Before the product is delivered, the machine has, for example, been inspected and adjusted by your retailer. See the certific[...]

English - 6 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. 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. Used in this publicati[...]

English - 7 SYMBOLS AND DECALS Read Shut off engine and Keep a safe Use on slopes No passengers Operator’s remove key before distance from no greater Manual performing any the machine than 10° maintenance or repair work Whole body Severing of fingers Do not open or Careful backing up, Careful going exposure to and toes remove safety watch for ot[...]

English - 8 SAFETY Safety Instructions These instructions are for your safety. Read them carefully. 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. WARNING! This symbol means that important safety instructions [...]

English - 9 SAFETY • Never leave a running machine unattended. Always turn off blades, set parking brake, stop engine, and remove keys before dismounting. • 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 guar[...]

English - 10 SAFETY Personal Safety Equipment • Make sure that you have first aid equipment close at hand when using the machine. • Never use the machine when barefoot. • Always wear protective shoes or boots, preferably with steel toe caps. • Always wear approved protective glasses • or a full visor when assembling or driving. • Always[...]

English - 11 SAFETY • 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[...]

English - 12 SAFETY Maintenance 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. • Never remove gas cap or[...]

English - 13 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. Clean oil or fuel spillage and rem[...]

English - 14 SAFETY • 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. • 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, pro[...]

English - 15 SAFETY n6 70303.52 l26 70m 12FETY[...]

English - 16 SAFETY Roll over 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 is the ROPS an accessory. • Do not use ROPS as a lifting, attaching or anchoring point. • Do not use ROPS for wrecking or towing. • Do not exceed Max GVW: 2822 lbs[...]

CONTROLS English - 17 Controls This operator’s manual describes the Dixon Zero Turn Rider. The rider is fitted with a Kawasaki four-stroke V- Twin engine developing 17-19 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 stee[...]

CONTROLS English - 18 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[...]

CONTROLS English - 19 Seat adjustment 8050-165 2. Seat adjustment lever The seat can be adjusted lengthways. When making adjustments, sit on the seat. Slide the lever to the side and maneuver seat to appropriate placement and release lever. 3. Bypass Linkages When pushing or pulling the mower, be sure to engage the IZT (Integrated Zeroturn Transaxl[...]

CONTROLS English - 20 4. Refueling The machine has one fuel tank, just behind the seat. The tank capacity is 4.5 gallons (17 liters). The engine will run on a minimum of 85-octane unleaded gasoline (no oil mix). Environmentally adapted alkylate gasoline can be used. See also Technical Data concerning ethanol fuel. Methanol fuel is not allowed. When[...]

CONTROLS English - 21 5. 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 cannot be manually reset. 6. Ignition Switch The ignition key i[...]

CONTROLS English - 22 9. Blade switch In order to engage the mower deck, pull the knob out; the mower blades are disengaged when the knob is depressed. 10. Circuit breaker The circuit breaker provides protection for the electrical system by (1) 15 amp circuit breaker. If the circuit breaker trips, push the button to reset. If the condition repeats,[...]

CONTROLS English - 23 12. Mower Deck Cut Height Lift Lever Located to the right and front of the operator, the lift lever controls the cutting height. The deck cutting height is obtained by pressing the foot pedal forward to lift the deck. To lower the deck, apply pressure to the top side of the foot pedal and allow it to pivot while depressing the[...]

English - 24 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 suggest that this section be reviewed in its entirety prior to attempting to move the mower [...]

English - 25 OPERATION Before Starting • Read the sections Safety Instructions and Controls before starting the machine. • Perform the daily maintenance before starting (see Maintenance Schedule in the Maintenance section). • Check that there is sufficient fuel in the fuel tank. • Adjust the seat to the desired position. The following condi[...]

English - 26 OPERATION • Move the steering controls outward to the locked (outer) neutral position. • Move the throttle to the middle position. • If the engine is cold, the throttle control should be pushed forward to its choke position. • Press in and turn the ignition key to the start position. Steering controls in the outward, locked neu[...]

English - 27 OPERATION • When the engine starts, immediately release the ignition key back to the run position. • Set the desired engine speed with the throttle. • Allow the engine to run at a moderate speed, “half throttle”, for 3-5 minutes before loading it too heavily. • USE FULL THROTTLE WHEN MOWING (no choke). Return to run positio[...]

English - 28 OPERATION[...]

English - 29 OPERATION Running 1. Release the parking brake by moving the lever downward. 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 parking brake will shut off the engine. 2. Move the steering controls to the neutral position (N). 3. S[...]

English - 30 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[...]

English - 31 OPERATION Mowing Tips • Observe and flag rocks and other fixed objects to avoid collisions. • Begin with a high cutting height and reduce it until the desired mowing result is attained. 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[...]

English - 32 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. • Disengage the mower deck by depressing the blade switch. • Raise the mower deck [...]

English - 33 OPERATION Moving by Hand When pushing or pulling the mower, be sure to engage the IZT (Integrated Zeroturn Transaxle) bypass linkages. • Always turn off engine before engaging or disengaging the hydro release. Never attempt to adjust the bypass linkages with the engine running. • The hydro release valves are located below the seat,[...]

English - 34 Daily Weekly A t Maintenance Interval Least In Hours Once Each Y ear Maintenance Page Before After 25 50 100 300 Check the parking brake z Check the engines oil level (every refueling) z Check the safety system z Check for fuel and oil leakages  Check/clean the engine’s cooling air intake z Check the mower deck z Check hardware (s[...]

English - 35 Daily Weekly A t Maintenance Interval Least In Hours Once Each Y ear Maintenance Page Before After 25 50 100 300 Check/adjust throttle cable z[...]

English - 36 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. • Keep battery and terminals clean. • Keep battery bolts tight. • Recharge at 6-10 amperes for 1 hour To clean battery and terminals Co[...]

English - 37 Ignition System The engine is equipped with an electronic ignition system. Only the spark plug requires maintenance. For recommended spark plug, see Technical Data. 1. Remove the ignition cable boot and clean around the spark plug. 2. Remove the spark plug with a spark plug socket wrench. 3. Check the spark plug. Replace the spark plug[...]

English - 38 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. Checking and Adjusting the Throttle Cable Check that the engine responds to throttle increases and that a good [...]

English - 39 Replacing the Air Filter If the engine seems weak or runs unevenly, the air filter may be clogged. If run with a dirty air filter, the spark plugs can become fouled, disrupting operation. For this reason, it is important to replace the air filter regularly (see the heading Maintenance Schedule for the proper service interval). Cleaning[...]

English - 40 4. Tap the paper filter against a fixed surface to remove dust. If the paper filter is still dirty, it must be replaced. Refit the air filter as follows: 1. Check that the seal on the bottom of the paper filter is whole. 2. Mount the paper filter in the air filter housing and tighten the wing nuts. 3. Refit the pre-filter on the paper [...]

English - 41 Checking Tire Pressures All four tires should have a pressure of 15 psi / 103 kPa /1 bar. Checking the Parking Brake Visually check that no damage is found on the lever, linages, or switch belonging to the parking brake. Perform a stand still test and check that there is a braking action. To adjust the parking brake, contact the Dixon [...]

English - 42 Deck belt removal 1. Park on a level surface. Apply parking brake. 2. Lower the deck into the lowest cutting position. 3. Remove bolts from belt shields and remove shields. 4. Remove any dirt or grass that may have accumulated around the cutter housings and entire deck surface. 5. Carefully roll the belt over the top of the cutter hous[...]

English - 43 Pump Belt To replace EZT (E-Series Zeroturn Transaxle) belt Park the mower on a level surface. Engage the parking brake. EZT belt removal NOTE: Be careful not to damage the fan blades on the EZT´s as this can affect cooling or damage the EZT´s • Remove the deck belt (see Deck Belt Removal in this section of the manual). • Create [...]

English - 44 Blade replacement • Remove blade bolt by turning counterclockwise. • 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.Torque blade bolt to 27-35 ft/lb (35-45 Nm). WARNING! Blades are sh[...]

English - 45 Adjusting the Mower Deck Check the tire pressure before adjustment of the mower deck. See “Checking Tire Pressure” in Maintenance section. Faulty mower deck adjustments will cause an uneven mowing result. To level deck Adjust the deck while the mower is on a level surface. Make sure the tires are inflated to the correct pressure. S[...]

English - 46 MAINTENANCE To adjust anti-scalp rollers Deck has 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 con[...]

English - 47 MAINTENANCE Cleaning and Washing Regular cleaning and washing, especially under the mower deck, will increase the machine’s lifespan. 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 [...]

English - 48 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. For daily use, the machine should be lubricated twice weekly. Wipe away excess g[...]

English - 49 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 [...]

English - 50 4. Deck outer spindle Lubricate using a grease gun, one zerk, each side 2-3 strokes. Use only good quality bearing grease. 5. Engine Oil Changing the Engine Oil The engine oil should be changed for the first time after 5-8 hours of operation. Thereafter, it should be changed every 50 hours. 1. Place the machine on a flat surface. 2. Pl[...]

English - 51 Checking the Oil Level Check the oil level in the engine when the machine is standing level and the engine is stopped. Remove the dipstick, wipe it clean, and then replace it. The dipstick should be screwed into place. Take the dipstick out again and read the oil level. The oil level should lie between the markings on the dipstick. If [...]

English - 52 6. Changing the Engine 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 [...]

English - 53 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 port plug (see illustration) from the left side and right side of the transaxles prior to filling with oil. This will allow the transaxles to vent during [...]

English - 54 Purging Procedures Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that it is purged from the system. These purge procedures should be implemented any time a hydrostatic system has been opened to facilitate maintenance or any additional oil has been added to the system. The resulting symptoms [...]

English - 55 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 parking brake is not activated. • The battery is dead. • Contamination in the carburetor or fuel line. • T[...]

English - 56 The engine seems weak. • Clogged air filter. • Defective spark plugs. • Carburetor incorrectly adjusted. • Air trapped in hydraulic system. The engine overheats. Battery not charging. • Poor contact with battery terminal cable connectors. The machine moves slowly, unevenly, or not at all. • Parking brake on. • Bypass valv[...]

English - 57 Uneven mowing results. • Different air pressure in the tires on the left and right sides. • Bent blades. • The suspending for the mower deck is uneven. • The chain fixture has come loose. • The blades are blunt. • Driving speed too high. • The grass is too long. • Grass collected under the mower deck. The machine vibrat[...]

English - 58 STORAGE Storage Winter Storage At the end of the mowing season, the machine should be readied for storage (or if it will not be in use for longer than 30 days). Fuel allowed to stand for long periods of time (30 days or more) can leave sticky residues that can plug the carburetor and disrupt engine function. Fuel stabilizers are an acc[...]

English - 59 SCHEMATIC FRONT HALF OF WIRING HARNESS ALL MODELS CODE COLOR A RED B RED C RED D BLLUE E BLUE F WHITE G WHITE H WHITE J WHITE K WHITE L WHITE M WHITE N RED/WHT P RED/WHT R YELLOW S YELLOW T YELLOW U YELLOW V YELLOW W GREEN X GREEN Y GREEN Z WHT/GRN AA WHT/GRN AB WHT/GRN AC WHT/GRN AD BROWN AE BROWN[...]

English - 60 SCHEMATIC REAR HARNESS MODELS: 968999564, 968999565, 968999618 REAR HARNESS MODELS: 968999566, 968999619 G F E M L M A H J A B K D D B C L H K C G J E CODE COLOR A RED B RED C RED D RED/WHT E WHITE F WHITE G WHITE H WHITE J YELLOW K YELLOW L GREEN M BLUE CODE COLOR A RED B RED C WHITE D WHITE E WHITE F BLUE G GREEN H YELLOW[...]

English - 61 SCHEMATIC REAR WIRING HARNESS MODELS: 968999690, 968999731 CODE COLOR A RED B RED C WHITE D WHITE E WHITE F BLUE G GREEN H YELLOW J RED/WHT[...]

English - 62 TECHNICAL DATA Engine Manufacturer Kohler Kohler Type Command Pro Command Pro Power 18 hp 18 hp Lubrication Pressure with oil filter Pressure with oil filter Oil capacity excl filter 1.9 (1.8 liters) 1.9 (1.8 liters) Oil capacity incl filter 2 qt (1.9 liters) 2 qt (1.9 liters) Engine oil, Synthetic 10W-30, 5W-20/5W-30 10W-30, 5W-20/5W-[...]

English - 63 TECHNICAL DATA Equipment Cutting width 3 4" 4 4" Cutting height 1.5" - 4.5" 1.5" - 4.5" Uncut circle 0 0 Number of blades 2 3 Blade length 17.38" 15.25" Nose rollers Yes Ye s American Craftsmen Seat Standard Standard Hinged armrests Yes Y es Hour meter Standard Standard Blade engagement Electric [...]

English - 64 TECHNICAL DATA Engine Manufacturer Kawasaki Kohler Type KA I Command Pro Power 16 hp 18 hp Lubrication Pressure with oil filter Pressure with oil filter Oil capacity excl filter 1.6 qt (1.5 liters) 1.9 (1.8 liters) Oil capacity incl filter 1.8 qt (1.7 liters) 2 qt (1.9 liters) Engine oil, Synthetic SAE3 30, 10W-30/10W-40 10W-30, 5W-20/[...]

English - 65 TECHNICAL DATA Equipment Cutting width 34" 34 " Cutting height 1.5" - 4.5" 1.5" - 4.5" Uncut circle 0 0 Number of blades 2 2 Blade length 17.38" 17.38" Nose rollers Yes Ye s Michigan Seat Standard Standard Hinged armrests Yes Y es Hour meter Standard Standard Blade engagement Electric clutch Elec[...]

English - 66 Engine Manufacturer Kawasaki Kawasaki Type KAI KA I Power 16 hp 19 hp Lubrication Pressure with oil filter Pressure with oil filter Oil capacity excl filter 1.7 qt (1.6 liters) 1.6 qt (1.5 liters) Oil capacity incl filter 1.9 qt (1.8 liters) 1.8 qt (1.7 liters) Engine oil, Synthetic SAE 30, 10w-30/10w-40 SAE 30, 10w-30/10w-40 SAE 5W-20[...]

English - 67 TECHNICAL DATA Equipment Cutting width 34" 4 4" Cutting height 1/5" - 4.5" 1/5" - 4.5" Uncut circle 0 0 Number of blades 2 3 Blade length 17.38" 15.25" Nose rollers Yes Yes Michigan Seat Standard Standard Hinged armrests Yes Yes Hour meter Standard Standard Blade engagement Electric clutch Electr[...]

English - 68 Engine Manufacturer Kawasaki Type KAI Power 16 hp Lubrication Press ure with oil filter Oil capacity excl filter 1.9 (1.8 liters) Oil capacity incl filter 2 qt (1.9 liters) Engine oil, Synthetic SAE 30, 10w-30/10w-40 SAE 5W-20 (winter) Engine oil, Mineral Class SF, SG, SH, SJ Fuel 87 octane minimum 10% max. ethanol 15% MTBE by volume 5[...]

English - 69 Equipment Cutting width 34" Cutting height 1.5" - 4.5" Uncut circle 0 Number of blades 2 Blade length 17.38" Nose rollers Yes Michigan Seat Standard Hinged armrests Yes Hour meter Standard Blade engagement Electric clutch Deck construction 7 gauge w/7 gauge skirts Productivity Productivity 2.75 acres/hr Overall dime[...]

English - 70 TECHNICAL DATA Accessories Collection system Torque Specifications ·Engine crankshaft bolt 50 ft/lb (67 Nm) ·Deck pulley bolts 45 ft/lb (61 Nm) ·Lug nuts 75 ft/lb (100 Nm) ·Blade bolt 45-55 ft/lb (60-75 Nm) ·Standard ¼” fasteners 9 ft/lb (12 Nm) ·Standard 5/16" fasteners 18 ft/lb (25 Nm) ·Standard 3/8" fasteners 33 [...]

English - 71 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, (Californian emission rules etc.). Do not remove any of these labels. Certificat[...]

English - 72 SERVICE JOURNAL Service Journal Action Date, mtr reading, stamp, sign Delivery Service 1. Charge the battery. 2. Adjust the tire pressure of all wheels to 15 PSI (1 bar). 3. Mount the steering controls in the normal position. 4. Connect the contact box to the cable for the seat’s safety switch. 5. Check that the right amount of oil i[...]

English - 73 SERVICE JOURNAL After the First 5-8 Hours 1. Change engine oil.[...]

English - 74 SERVICE JOURNAL Action Date, mtr reading, stamp, sign 25-Hour Service 1. Check the fuel pump’s air filter. 2. Sharpen/Replace mower blades if required. 3. Check the tire pressures. 4. Check battery with cables. 5. Lubricate according to lubrication chart. 6. Check/clean the engine’s cooling air intake. 7. Clean the air cleaner’s [...]

English - 75 SERVICE JOURNAL Action Date, mtr reading, stamp, sign 50-Hour Service 1. Perform the 25-hour service. 2. Clean/replace the air cleaner’s filter cartridge (paper filter) (shorter intervals for dusty operating conditions). 3. Change engine oil. 4. Lubricate according to lubrication chart. 5. Check/adjust the parking brake.[...]

English - 76 Action Date, mtr reading, stamp, sign 100-Hour Service 1. Perform the 25-hour service. 2. Perform the 50-hour service. 3. Change the engine oil filter. 4. Clean/replace the spark plugs. 5. Replace the fuel filter. 6. Clean the cooling fins on the engine and transmission. 7. Check V-belts. 8. Check tighten caster wheel axle bolts (every[...]

English - 77 Action Date, mtr reading, stamp, sign 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. Check/adjust the mower deck. 6. Clean the combustion chamber and grind t[...]

English - 78 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 (foam) (300 hours). 3. Replace the air filter’s paper cartridge. 4. Change the engine oil (50 hours). 5. Replace the engine oil filter (100 hours). 6. Check/adj[...]

English - 79 SERVICE JOURNAL Action Date, mtr reading, stamp, sign[...]

Part No. 539 118101 R01 (08/14/07)[...]