Dixon ZTR 3500 Series manual

3500 SERIES ZTR ® 2003 OPERATORS MANUAL[...]

IMPORTANT - READ CAREFULLY 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 the operators manual carefully and become completely familiar with the controls. The information contained in this [...]

3 INDEX Page Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . . . . . . . .14 Controls. .[...]

4 RIDING LAWN MOWERS, IF IMPROPERLY OPERATED, CAN CAUSE SERIOUS INJURY OR DEATH. The most common causes of injury to the operator or bystander... ...read and understand this manual to prevent injuries. BLADE CONTACT TIP OVER RUN OVER BACK OVER SAFETY[...]

5 Safety Alert Symbol When you see this symbol, BE ALERT to the potential for injury. 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 potentially hazardous situation which, if not avoided, could result in death or serio[...]

6 Failure to observe the following safety instructions could result in serious injury or death. GENERAL OPERATION: Read, understand, and follow all instructions in the 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 rocks[...]

7 GENERAL OPERATION (continued) : Turn off blades when not mowing. Stop engine before removing grass catcher or unclogging chute. Mow only in daylight or good artificial light. Do not operate the mower while under the influence of alcohol or drugs. Watch for traffic when operating near or crossing roadways. Use extra care when loa[...]

8 SLOPE OPERATION: 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 cannot back up the slope or if you feel uneasy on it, do not mow it! DO  Mow across the slope with your Dixon ZTR - never up or down.  Remove obstacles such as roc[...]

9 SAFETY 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 adul[...]

10 SERVICE: Use extra care in handling gasoline and other fuels. They are flammable and vapors are explosive. Use only an approved container. Never remove fuel cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke while refueling. Never refuel the mower indoors. Never store the mower or fuel container inside a [...]

11 SERVICE (continued): Never run a mower inside a closed area. The exhaust fumes are toxic. 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. Keep mower free of grass, leaves, or other debris buildup. Clean up oil[...]

12 WARRANTY: Home Owner Application: Dixon ZTR Residential Hydro Units, used only at owners primary place of residence are warranted for a period of two (2) years from date of purchase. Commercial Application: defined as use other than, or in addition to, mowing at owners primary place of residence. Dixon ZTR Residential Hydro Units, used in [...]

13 SPECIFICATIONS Model ZTR 3530 & 3536 CHASSIS: 1X2X11 gauge welded tube, 7 gauge transmission and engine base plate. BODY: All body parts made of high density polyethylene. Dent and corrosion resistant. MOWER DECK: 30 Deck: 11 GA Stamped Steel Construction-30 Cut Width. 36 Deck: 11 GA Fabricated Construction/Reinforcement Ribs-36 [...]

14 SEAT ADJUSTMENT INSTRUCTIONS 1. Move deck lift lever to lowest cut position. 2. Rotate seat assembly forward. 3. Loosen four bolts and slide seat forward or backward to desired position. 4. Re-tighten bolts. 5. Push seat assembly back to closed position.[...]

15 CONTROLS CONTROL LEVERS Note: The control levers must be in the outward position to access the seat. This also activates the parking brake. (levers out = brakes on or levers in = brakes off) TO GO FORWARD:  Rotate levers inward.  From neutral position, gently push both control levers forward.  To increase speed, move levers further forw[...]

16 CONTROLS PARKING BRAKE: The parking brake is incorporated into the control levers. To set brakes, move levers to neutral and swing outward. To release brake, rotate levers inward. MOWER DECK CUT HEIGHT LIFT LEVER : Located between operators legs. Grab handle and lift and pull release Set at desired position and release latch. NOTE: A[...]

17 CONTROLS BLADE DRIVE: Located on the control panel, on operators right. To engage the mower blade, pull up on the switch. To disengage mower blade, push down. CIRCUIT BREAKER : Protection of the electrical system is by (1) 15 amp circuit breaker. If circuit breaker trips, push button to reset. If this condition repeats, cons[...]

18 OPERATION INSTRUCTIONS The safe and successful operation of the 3500 Series 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. During initial o[...]

19 OPERATION INSTRUCTIONS TOWING TRAILERS AND OTHER ATTACHMENTS: Towing a trailer or other attachment that is too heavy could damage the drive or cause the mower to become unstable. Limit loads to 250 pounds or less with this mower. TO FREE WHEEL MACHINE (Unlock Transmission): Always turn off engine before engaging or disengaging the hydro release [...]

20 OPERATION INSTRUCTIONS TESTING OF SAFETY INTERLOCK SYSTEMS: PARKING BRAKE SWITCH TEST: a) Swing control levers inward. b) Disengage blade drive switch c) Turn ignition switch to START Engine should not turn over or attempt to start. BLADE DRIVE SWITCH TEST: a) Swing control levers outward b) Engage blade drive switch c) Turn ignition switch to S[...]

21 STARTING INSTRUCTIONS: 1. To start engine the control levers must be in the outward position with the park brake on and the mower blade off. 2. Move throttle control to choke position if engine is cold, full throttle if warm. 3. Insert ignition key and turn to start position. When engine starts, release ignition key. Key will return [...]

22 OPERATION INSTRUCTIONS GRASS HEIGHT AND 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. Mow at a reduced speed. Kee[...]

23 OPERATION INSTRUCTIONS MOWING - SIDE DISCHARGE: CAUTION Be sure that the deflector is properly installed on the discharge chute. 1, Set engine speed control to the wide open or full setting. 2. Do Not Attempt To Cut Grass When It Is Wet. Wet grass will clog the underside of the deck and discharge area causing mower to slip on hills. 3. If the gr[...]

24 OPERATION INSTRUCTIONS MOWING - MULCHING ATTACHMENT: 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 of the recycled or mulched clippings. In order to achieve the best r[...]

25 OPERATION INSTRUCTIONS MOWING - MULCHING ATTACHMENT ( continued): 6. 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. 7. Alternate mower direction. This will evenly disperse the mulched grass clippings over the lawn for even fertilization. If [...]

26 OPERATION INSTRUCTIONS MOWING - GRASS CATCHER ATTACHMENT: In order to achieve optimum performance when mowing with a grass catching attachment, please read and follow the tips listed below. 1. Set engine speed control to the wide open or full setting. 2. Do Not Attempt To Cut Grass When It Is Wet. Wet grass will clog both the underside of the de[...]

27 CAUTION  Disengage blades and turn engine off when emptying bags.  The handling is affected with the added weight of the grass bags. Empty the bags when the front of the mower becomes light.  Watch for low hanging branches or other obstacles which might hit the catcher top while turning or backing the mower.  Use care when backing to[...]

28 CARE AND MAINTENANCE CAUTION CAUTION CAUTION CAUTION CAUTION Bef Bef Bef Bef Bef ore perf ore perf ore perf ore perf ore perf or or or or or ming an ming an ming an ming an ming an y maintenance y maintenance y maintenance y maintenance y maintenance , tur , tur , tur , tur , tur n off engine n off engine n off engine n off engine n off engine ,[...]

29 CARE AND MAINTENANCE ENGINE: For complete maintenance and operating information of the engine, please refer to the maintenance instructions furnished by the engine manufacturer and included in your Zero Turn Radius mower information packet. BATTERY: This is a maintenance-free battery and the fluid level cannot be checked. Charge battery if[...]

30 CARE AND MAINTENANCE 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 excessively. DANGEROUS! DO NOT USE BLADE IN THIS CONDITION! When notch starts, discard blade New Blade Check sharpn[...]

31 CARE AND MAINTENANCE PARKING BRAKE ADJUSTMENT: 1. Remove rear wheel. 2. Swing control levers in to operating position. There must be clearance between the teeth of the brake ratchet and brake sprocket. 3. If adjustment is necessary, loosen two screws, as illustrated. 4. Slide adjustable link to provide clearance between brake teeth. 5. Tighten s[...]

32 CARE AND MAINTENANCE NEUTRAL ADJUSTMENT DRIVE MACHINE UNTIL HYDROSTATS HAVE WARMED UP. WITH ENGINE RUNNING, SWING THE CONTROL LEVERS IN TO THE OPERATING POSITION. IF MACHINE STARTS TO CREEP, FOLLOW THE INSTRUCTIONS BELOW. 1. Stop the engine and swing the control levers out to engage the parking brake. Raise rear of frame with jack or blocks so t[...]

33 CARE AND MAINTENANCE 4. Stop engine and remove rear of machine from jack or blocks. 5. Drive machine with both control levers in top speed position. If one side now drives slightly faster than the other, rotate lever stop washer on that side to reduce forward range of control lever. If levers are now uneven at top speed, loosen control lever mou[...]

34 CARE AND MAINTENANCE MOWER DECK LEVELING PROCEDURE: 1. Place mower on a smooth, level surface and check tire pres- sures to insure correct stance. Tires should be inflated as follows. Front: 16 - 21 l bs Rear: 8 - 14 lbs 2. Turn each outer blade tip to align with the deck in a side to side manner. 3. Measure from the floor surface up to the bott[...]

35 CARE AND MAINTENANCE DECK REMOVAL: 1 . Move deck lift lever to lowest cut position. 2. Rotate seat assembly forward. 3. Pull idler to relieve belt tension. Remove belt. 4. Remove cotter pin, washer and clevis pin from rear deck brackets (2 places). Note: Raising the front of the deck slightly to sit on blocks will take the pressure off clevis pi[...]

36 CAUTION HOT oil may cause burns. Allow engine to cool before draining oil. Hex Head Valve Stem PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS. PROTECT YOUR ENVIRONMENT. CARE AND MAINTENANCE CHANGING THE ENGINE OIL: 1. The Dapco oil drain valve is located on the front of engine on the right side. 2. Place a suitable container unde[...]

37 CARE AND MAINTENANCE LUBRICATION: LOCATIONS: (1) each front wheel caster (1) each mower deck hub SERVICE INTERVALS: Every 50 hours of operation RECOMMENDED GREASE: Name brand wheel bearing or multi- purpose grease. Once per season or 50 hours of operation (3 pumps each) BELTS: Check belts every 50 hours. Replace any belts found to be in poor con[...]

38 CARE AND MAINTENANCE ELECTRICAL SYSTEMS: Keep all connections clean and tight. CLEANING THE MOWER: Wash 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 minutes to[...]

39 STANDARD SERVICE PARTS LIST 30 Deck: Blades: Hi-Lift (standard) - P/N 2484 Lo-Lift - P/N 2483 Belts: Engine to Transmission - P/N 7650 Engine to Jackshaft - P/N 14524 Jackshaft to Mower Deck - P/N 14523 36 Deck: Blades: Lo-Lift (standard) - P/N 1324 *Hi Lift - P/N 1351 (Right) *Hi-Lift - P/N 1352 (Left) * Use with grass catcher only! Belts[...]

40 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- - - - - - - - - - - - - - - - - - - - - - -[...]

41 TROUBLESHOOTING 6. ENGINE RUNS BUT MOWER WONT MOVE FORWARD Drive belt broken or slipping- - - - - - - - - - - - - - - - - - - - replace drive belt Bad transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer Transmission by-pass may be on- - - - - - - - - - - -turn off (see page 19) 7. MOWER LOSES POWER O[...]

42 NOTES[...]

43 OWNER INFORMATION Date Purchased _______________________________ Mower Model Number _________________________ Mower Serial Number ____________________________ Purchased From ___ _____________________________ Name _________________________________ Address ________________________________ DATE OIL CHANGED: DATE ENGINE TUNED: ___________________ __[...]

ZTR®Mowers ZTR®Mowers ZTR®Mowers ZTR®Mowers ZTR®Mowers Dixon® and ZTR® are registered trademarks of Dixon Industries, Inc. DIXON INDUSTRIES, INC. a BLOUNT International Inc. Co. P.O. Box 1569 Coffeyville, Ks 67337-0945 620-251-2000 3500 Series 3530 & 3536 Part No. 13641-0802 W W W W W ARNING: ARNING: ARNING: ARNING: ARNING: The engine ex[...]