Dixon ZTR Safety And Operating Manual
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Dixon ZTR Safety And Operating Manual

Dixon diesel ztr safety instructions & operator's manual
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KODIAK
DIESEL ZTR
™
®

Safety Instructions

&
Operator's Manual

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Summary of Contents for Dixon ZTR

  • Page 1: Safety Instructions

    KODIAK DIESEL ZTR ™ ® Safety Instructions & Operator’s Manual...
  • Page 2 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 this Operator’s Manual carefully.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SAFETY & WARNING...4-15 WARRANTY...16 SPECIFICATIONS...17 SEAT ADJUSTMENT...18 CONTROLS...19-21 OPERATION INSTRUCTIONS...22-32 CARE & MAINTENANCE...33-46 TROUBLESHOOTING...47-48 STANDARD SERVICE PARTS LIST...49 KODIAK™ DIESEL Part Number 18626-1005 Page...

  • Page 4: Safety & Warning

    SAFETY RIDING LAWN MOWERS, IF IMPROPERLY OPERATED CAN CAUSE SERIOUS INJURY OR DEATH Pictured below are the most common causes of injury to the operator or bystander. Please read and understand this manual to prevent injuries. Blade Contact Tip Over Run Over Back Over...

  • Page 5: Safety Alert Symbol

    SAFETY 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.

  • Page 6: General Operation

    WARNING Failure to observe the following safety instructions could result in serious injury or death. GENERAL OPERATION: 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.
  • Page 7 WARNING Failure to observe the following safety instructions could result in serious injury or death. GENERAL OPERATION (continued): Never leave a running mower unattended. Always turn off blades, set parking brake, stop engine and remove key before dismounting. Turn off blades when not mowing. Injury could occur from contact with moving parts.
  • Page 8 WARNING Failure to observe the following safety instructions could result in serious injury or death. GENERAL OPERATION (continued): 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.

  • Page 9: Slope Operation

    Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in All slopes require extra caution. If you feel uneasy Mow across the slope with your Dixon® ZTR® -- never up or down. This will decrease the risk of tip-over.
  • Page 10 WARNING Failure to observe the following safety instructions could result in serious injury or death. SLOPE OPERATION (continued): DO (continued): 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 attachments to prevent tip-over or roll-over.
  • Page 11 WARNING Failure to observe the following safety instructions could result in serious injury or death. SLOPE OPERATION (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.

  • Page 12: Fire Hazards

    WARNING Failure to observe the following safety instructions could result in serious injury or death. 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.
  • Page 13 Failure to observe the following safety instructions could result in serious injury or death. FIRE HAZARDS (continued): To prevent fire or explosion, keep sparks 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.
  • Page 14 WARNING Failure to observe the following safety instructions could result in serious injury or death. 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.
  • Page 15 WARNING Failure to observe the following safety instructions could result in serious injury or death. 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.

  • Page 16: Warranty

    First two years - 100% parts and labor subject to the conditions and limitations described herein with the exception of non-covered items specified below. Third year - limited to 100% parts cost as shown in the current Dixon® Parts Price List and subject to the conditions and limitations as described herein.

  • Page 17: Specifications

    Rear 23 X 10 X 10 Turf Master (8-14 lbs) CAPACITIES: Fuel - 11 gallon (approximately) Hydrostat Oil tank - 4 quart with in-line 25 micron filter & Dixon Blue Engine - 2 qts. SAE 10W30 (with filter) Radiator - 50/50 mix DIMENSIONS:...

  • Page 18: Seat Adjustment

    SEAT ADJUSTMENT INSTRUCTIONS 1. Grasp seat slide adjuster and move it into adjustment position. 2. Slide seat forward or backward. 3. Release seat slide adjuster.

  • Page 19: Controls

    CONTROL LEVERS Note: For access to the seat, move control levers to neutral position and swing them outward. TO GO FORWARD •From neutral position, gently push control levers for- ward. •To increase speed, move levers further forward. TO GO BACKWARDS •From neutral position, gently pull control levers toward you.

  • Page 20: Parking Brake

    PARKING BRAKE: The parking brake is designed to hold the mower from moving and is not intended for use in stopping the mower while it is in motion. The engine will stop if the parking brake is engaged while the control levers are in the drive position.

  • Page 21: 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: •Located on the control panel to the operator’s right. •Protection of the electrical system is by (1) 15 amp circuit breaker.

  • Page 22: Operation Instructions

    OPERATION INSTRUCTIONS 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.

  • Page 23: Starting Instructions

    OPERATION INSTRUCTIONS CAUTION STARTING 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 to 15 seconds. 4.
  • Page 24 Turn ignition switch to START Engine should not turn over or attempt to start. NOTE: If any safety check fails, do not operate the mower until the system has been checked and repaired by an Authorized Dixon® Dealer. of each mowing day.
  • Page 25 Engage blade drive. d) Raise slightly off seat. NOTE: If any safety check fails, do not operate the mower until the system has been checked and repaired by an Authorized Dixon® Dealer. of each mowing day. ENGINE SHOULD STOP!

  • Page 26: Mowing With A Mulching Attachment

    OPERATION INSTRUCTIONS MOWING WITH A 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 the recycled or mulched clippings.
  • Page 27 OPERATION INSTRUCTIONS MOWING WITH A MULCHING ATTACHMENT (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 impeller are still turning.
  • Page 28 OPERATION INSTRUCTIONS MOWING WITH A GRASS CATCHER ATTACHMENT: In order to achieve optimum performance when mowing with a grass catching attachment, please read and follow the tips listed below. Read and follow the installation instructions that are included with your grass catcher. Set engine speed control to the wide open or full setting.
  • Page 29 OPERATION INSTRUCTIONS MOWING WITH A GRASS CATCHER ATTACHMENT (continued): 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.

  • Page 30: Side Discharge Of The Clippings

    OPERATION INSTRUCTIONS 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 Troubleshooting guide. CAUTION 1. Set engine speed control to the wide open or full setting.
  • Page 31 OPERATION INSTRUCTIONS 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.
  • Page 32 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 500 pounds or less with this mower. TO FREE WHEEL MACHINE (Unlock Transmission): Always turn off engine before engaging or disengaging the hydro release (free wheel) lever.

  • Page 33: Care & Maintenance

    CARE AND MAINTENANCE WARNING 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 with tools.

  • Page 34: Cutter Blade Maintenance

    CARE AND MAINTENANCE CUTTER BLADE MAINTENANCE: CAUTION Stop engine and remove ignition key Check sharpness of mower blades after every 10 hours of operation. Observe proper blade position prior to removal. 1. Safely raise front of mower. 2. Hold or block blade from turning.

  • Page 35: Care And Maintenance

    •Charge battery. Note: Your Dixon® mower comes equipped with a quick disconnect harness for the optional Dixon® Battery Manager. The Dixon® Battery Manager maintains the proper charge levels during periods of inactivity and may prevent premature battery failures.

  • Page 36: Tires/Lubrication

    CARE AND MAINTENANCE 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 Rear tires Lug nuts or lug bolts should be checked regularly for tightness. LUBRICATION: CHASSIS: LOCATIONS:...

  • Page 37: Belt Tension

    CARE AND MAINTENANCE BELTS: Check belts every 50 hours. Replace any belts found to be in poor condition. BELT TENSION: Engine to Mower Deck Belt: To adjust tension of the mower deck drive belt, turn adjuster nut on threaded eyebolt. Turning nut to the right will make the belt tighter.

  • Page 38: Changing The Engine Oil

    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. To drain, turn hex head valve stem counter-clockwise with a 10mm wrench or socket.

  • Page 39: Oil Filters

    NOTE: Engine oil changes on the KODIAK™ will require replacement of the oil filter. These filters may be available from your local Dixon® Dealer. OIL FILTERS: 1. Replace filter each time the oil is changed. 2. Oil Filters can be obtained from your authorized engine dealer.

  • Page 40: Hydrostatic Transmission Fluid

    Normal Operating Temperatures - 20W50 engine oil Cold climate usage - 10W40 engine oil Use engine oil with an API classification of SG/CD. Dixon Blue™ 15W-50 Synthetic Hydrostatic Fluid is specifically formulated to provide excellent all-climate performance and extended time between...

  • Page 41: Hydrostat Fluid Maintenance

    500 hours after that. Remove the filter and be sure all fluid has drained from the reservoir. Replace with a new OEM filter (P/N 18045) and Dixon Blue™ 15W-50 Synthetic Hydrostatic Fluid. CAUTION: Dixon Blue™ is only compatible with standard 20W-50 motor oil or similar synthetic motor oils.

  • Page 42: Neutral Adjustment

    CARE AND MAINTENANCE 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.
  • Page 43 CARE AND MAINTENANCE 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. Tighten set screw on lock collar. 3. Repeat for opposite side. 4.

  • Page 44: Leveling The Deck

    CARE AND MAINTENANCE 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.

  • Page 45: Mower Deck Removal

    CARE AND MAINTENANCE MOWER DECK REMOVAL: 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).

  • Page 46: Care & Maintenance

    SERIAL NUMBERS: The serial number is located on frame at rear of engine. WARRANTY: Refer to warranty information (pages 16). PARTS/SERVICE: See your Dixon® dealer for replacement parts, warranty or service.

  • Page 47: Troubleshooting

    TROUBLESHOOTING 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 Solenoid- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer...
  • Page 48 TROUBLESHOOTING 6. ENGINE RUNS BUT MOWER WON’T MOVE FORWARD Drive belt broken or slipping- - - - - - - - - - - - - - - - replace drive belt Transmission oil low- - - - - - - - - - - - - - - - - - - - - - - - - - - - add oil Damaged transmission- - - - - - - - - - - - - - - - - - - - - -consult dealer Transmission by-pass may be engaged- - - - disengage (see page 32)

  • Page 49: Standard Service Parts List

    STANDARD SERVICE PARTS LIST Blades *Hi-Lift Fuson - P/N 10782 Gator Fusion - P/N 10947 Lo-Lift Fusion - P/N 10881 *Factory installed Belts Engine to Mower Deck - P/N 11339 Engine to Hydros - P/N 10923 ENGINE AIR AND OIL FILTERS Refer to Engine Operator’s Manual for correct service intervals for engine oil changes and air filter maintenance.
  • Page 50 NOTES...
  • Page 51 OWNER’S INFORMATION Date of Purchase Mower Model Number Mower Serial Number Purchased From DATE OIL CHANGED Dixon Industries, Inc.~P.O. Box 1569~Coffeyville, Ks~620-251-2000~Fax 620-251-4117 Name Address DATE ENGINE TUNED...
  • Page 52 Dixon® and ZTR® are registered trademarks of WARNING: DIXON INDUSTRIES, INC. P.O. Box 1569 Coffeyville, Ks 67337-0945 620-251-2000 Dixon Industries, Inc. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

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