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Troubleshooting
Related Manuals for Dixon ZTR34/968999564
Summary of Contents for Dixon ZTR34/968999564
- Page 1 BLACK BEAR ™ ® ™ BLACK BEAR ® Operator’s Manual ZTR34/968999564 ZTR44/968999565 ZTR34/968999566 ZTR34/968999618 ZTR34/968999619 ZTR44/968999690 ZTR34/968999731 English Please read the operator’s manual carefully and make sure you understand the instructions before using the machine.
- Page 2 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.
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Page 3: Table Of Contents
Introduction ... 4 Congratulations ... 4 Use ... 4 Good service ... 5 Serial number ... 5 Symbols and decals ... 6 Translation of instructions ... 7 Safety instructions ... 8 General use ... 8 Personal Safety ... 10 Operation ... 10 Children ... -
Page 4: Introduction
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. -
Page 5: Good Service
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 certificate in the Service Journal in this operator’s manual. -
Page 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. WARNING! Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx xxxxxxxxx. xx xxxxxxxx xxxx xxxxxx. 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. -
Page 7: Translation Of Instructions
SYMBOLS AND DECALS Read Shut off engine and Operator’s remove key before Manual performing any maintenance or repair work Whole body Severing of fingers exposure to and toes thrown objects Moving sharp blades under cover Keep a safe Use on slopes distance from no greater the machine... -
Page 8: Safety Instructions
Safety Instructions These instructions are for your safety. Read them carefully. WARNING! This symbol means that important safety instructions need to be emphasized. It concerns your safety. IMPORTANT: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROWING OBJECTS. - Page 9 • 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 guard.
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Page 10: Personal Safety
Personal Safety Equipment WARNING! When using the machine, approved personal protective equipment (shown in illustrations) shall be used. Personal protective equipment cannot eliminate the risk of injury but it will reduce the degree of injury if an accident does happen. Ask your retailer for help in choosing the right equipment. -
Page 11: Children
• 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. •... -
Page 12: Maintenance
Maintenance WARNING! The engine must not be started when the driver’s floor plate or any protective plate for the mower deck’s drive belt is removed. 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. -
Page 13: General Maintenance
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. - Page 14 • 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, protective cowlings, safety switches, or other protective...
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Page 15: Movement/Transport
• The blades are sharp and can cause cuts and gashes. Wrap the blades or use protective gloves when handling them. • Check the parking brake’s functionality regularly. Adjust and service as necessary. • The mulch blades should only be used in familiar areas when higher quality mowing is desired. -
Page 16: Customer Responsibilites
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. -
Page 17: Controls
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. -
Page 18: Motion Control Levers
Recommended air pressure is 15 psi (1 bar). Tracking must be checked on a flat and level concrete or blacktop surface. If unit still does not track straight, contact a Dixon dealer for adjustment. English... -
Page 19: Seat Adjustment Lever
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 Transaxle) bypass linkages. - Page 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.
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Page 21: Hour Meter
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. -
Page 22: Blade Switch
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. - Page 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 trigger and moving the lever forward.
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Page 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 under its own power. Additionally, we suggest when first operating the mower, use a reduced throttle speed and reduced ground speed by NOT moving control levers to the furthest forward or reverse positions during initial operation, or until operator becomes comfortable with controls. -
Page 25: Before You Start
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. - Page 26 • 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.
- Page 27 • When the engine starts, immediately release the ignition key back to the run position. IMPORTANT INFORMATION Do not run the starter for more than 5 seconds each time. If the engine does not start, wait about 10 seconds before retrying.
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Page 28: Start Engine With Weak Battery
To start an engine with a weak battery WARNING! Lead-acid batteries generate explosive gases. Keep sparks, flame and smoking materials away from batteries. Always wear eye protection then around batteries. If your battery is too weak to start the engine, it should be recharged. -
Page 29: Running
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. -
Page 30: Operating On Hills
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 control forward from its neutral... -
Page 31: Mowing Tips
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"... -
Page 32: Stopping The Engine
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. -
Page 33: Moving By Hand
Moving by Hand WARNING! Make no adjustments without: ♦ ♦ ♦ ♦ ♦ the engine stopped ♦ ♦ ♦ ♦ ♦ the ignition key removed ♦ ♦ ♦ ♦ ♦ the parking brake activated When pushing or pulling the mower, be sure to engage the IZT (Integrated Zeroturn Transaxle) bypass linkages. -
Page 34: Maintenance
Maintenance Schedule The following is a list of maintenance procedures that must be performed on the machine. For those points not described in this manual, visit an authorized service workshop. An annual service carried out by an authorized service workshop is recommended to maintain your machine in the best possible condition and to ensure safe operation. - Page 35 Maintenance Check/adjust throttle cable Check the condition of belts, belt pulleys, etc. Change the engine oil Replace the engine oil filter Clean/replace the spark plugs Replace the air filter (paper filter) Check the caster wheels (every 200 hours) Clean the cooling fins Replace the air cleaner’s pre-filter Check/adjust the mower deck Check the engine valve clearance...
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Page 36: Battery
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. •... -
Page 37: Ignition System
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. -
Page 38: Checking Engine's Cooling Air Intake
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 engine speed is attained at full throttle. -
Page 39: Replacing Air Filter
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). -
Page 40: Replacing The Fuel Filter
IMPORTANT INFORMATION! Do not use compressed air to clean the air filter. Do not wash the paper filter. Do not oil the paper filter. 4. Tap the paper filter against a fixed surface to remove dust. If the paper filter is still dirty, it must be replaced. -
Page 41: Checking Tire Pressures
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 service workshop. WARNING! Faulty adjustment can cause an accident. -
Page 42: Deck Belt Installation
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. -
Page 43: Pump Belt
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 •... - Page 44 Blade replacement WARNING! Blades are sharp. Protect your hands with gloves and/or wrap blades with a heavy cloth when handling. • 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.
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Page 45: Adjusting Mower Deck
Adjusting the Mower Deck WARNING! Before performing any service or adjustment, check the following list: 1. Engage the parking brake. 2. Place the blade switch in the disengaged position. 3. Turn ignition switch to “OFF” position and remove the key. 4. - Page 46 3. Turn both outer blades to align with the deck in front-to-rear manner. Reposition rear mounting bolts up or down until rear of mower deck is positioned level to " higher in the rear than the side-to-side measurement. 4. Comfirm measurements once again. Blade tips should be level in a side-to-side manner.
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Page 47: Cleaning & Washing
Engine oil cooler Kohler engine only. 1. Clean the outside of fins with a brush. 2. Remove the two screws holding the cooler unit to the blower housing. 3. Tilt the cooler downward. 4. Clean the inside of the cooler with a brush or with compressed air. -
Page 48: Lubrication
12/12 Every year Lubricate with grease gun 1/52 Every Week 1/365 Every day *Change transaxles (transmission) filters. 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. - Page 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.
- Page 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.
- Page 51 LUBRICATION 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.
- Page 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.
- Page 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.
- Page 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.
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Page 55: Troubleshooting
TROUBLE SHOOTING GUIDE Trouble Shooting Guide Problem The engine will not start. The starter does not turn the engine over. The engine runs rough. Cause • The blade switch is engaged. • The steering controls are not locked in the neutral position. -
Page 56: Trouble Shooting Guide
TROUBLE SHOOTING GUIDE The engine seems weak. The engine overheats. Battery not charging. The machine moves slowly, unevenly, or not at all. Mower deck not engaging. Transaxle leaks oil. English • Clogged air filter. • Defective spark plugs. • Carburetor incorrectly adjusted. •... - Page 57 TROUBLE SHOOTING GUIDE Uneven mowing results. The machine vibrates. • 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. •...
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Page 58: Storage
Service When ordering spare parts, please specify the purchase year, model, type, and serial number. Always use genuine Dixon spare parts. An annual check-up at an authorized service workshop is a good way to ensure that your machine performs its... -
Page 59: Schematic
SCHEMATIC FRONT HALF OF WIRING HARNESS ALL MODELS CODE COLOR BLLUE BLUE WHITE WHITE WHITE WHITE WHITE WHITE WHITE RED/WHT RED/WHT YELLOW YELLOW YELLOW YELLOW YELLOW GREEN GREEN GREEN WHT/GRN WHT/GRN WHT/GRN WHT/GRN BROWN BROWN English... - Page 60 REAR HARNESS MODELS: 968999564, 968999565, 968999618 REAR HARNESS MODELS: 968999566, 968999619 D B C English SCHEMATIC CODE COLOR RED/WHT WHITE WHITE WHITE WHITE YELLOW YELLOW GREEN BLUE CODE COLOR WHITE WHITE WHITE BLUE GREEN YELLOW...
- Page 61 SCHEMATIC REAR WIRING HARNESS MODELS: 968999690, 968999731 CODE COLOR WHITE WHITE WHITE BLUE GREEN YELLOW RED/WHT English...
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Page 62: Technical Data
Technical Data Engine Manufacturer Type Power Lubrication Oil capacity excl filter Oil capacity incl filter Engine oil, Synthetic Engine oil, Mineral Class Fuel Fuel tank capacity Spark plugs/gap Cooling Air filter Alternator Starter Transmission Transmission Speed and direction controls Speed forward Speed reverse Brakes Front caster tires, smooth tread... - Page 63 Equipment Cutting width Cutting height Uncut circle Number of blades Blade length Nose rollers American Craftsmen Seat Hinged armrests Hour meter Blade engagement Deck construction Productivity Productivity Overall dimensions Weight Base machine length Base machine width Base machine height Overall width, chute up Overall width, chute down TECHNICAL DATA BLACK BEAR 34/ 968999564...
- Page 64 Technical Data Engine Manufacturer Type Power Lubrication Oil capacity excl filter Oil capacity incl filter Engine oil, Synthetic Engine oil, Mineral Class Fuel Fuel tank capacity Spark plugs/gap Cooling Air filter Alternator Starter Transmission Transmission Speed and direction controls Speed forward Speed reverse Brakes Front caster tires, smooth tread...
- Page 65 Equipment Cutting width Cutting height Uncut circle Number of blades Blade length Nose rollers Michigan Seat Hinged armrests Hour meter Blade engagement Deck construction Productivity Productivity Overall dimensions Weight Base machine length Base machine width Base machine height Overall width, chute up Overall width, chute down TECHNICAL DATA BLACK BEAR 34/ 968999566...
- Page 66 Technical Data Engine Manufacturer Type Power Lubrication Oil capacity excl filter Oil capacity incl filter Engine oil, Synthetic Engine oil, Mineral Class Fuel Fuel tank capacity Spark plugs/gap Cooling Air filter Alternator Starter Transmission Transmission Speed and direction controls Speed forward Speed reverse Brakes Front caster tires, smooth tread...
- Page 67 Equipment Cutting width Cutting height Uncut circle Number of blades Blade length Nose rollers Michigan Seat Hinged armrests Hour meter Blade engagement Deck construction Productivity Productivity Overall dimensions Weight Base machine length Base machine width Base machine height Overall width, chute up Overall width, chute down TECHNICAL DATA BLACK BEAR 34/ 968999619...
- Page 68 Technical Data Engine Manufacturer Type Power Lubrication Oil capacity excl filter Oil capacity incl filter Engine oil, Synthetic Engine oil, Mineral Class Fuel Fuel tank capacity Spark plugs/gap Cooling Air filter Alternator Starter Transmission Transmission Speed and direction controls Speed forward Speed reverse Brakes Front caster tires, smooth tread...
- Page 69 Equipment Cutting width Cutting height Uncut circle Number of blades Blade length Nose rollers Michigan Seat Hinged armrests Hour meter Blade engagement Deck construction Productivity Productivity Overall dimensions Weight Base machine length Base machine width Base machine height Overall width, chute up Overall width, chute down TECHNICAL DATA BLACK BEAR 34/ 968999731...
- Page 70 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"...
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Page 71: Conformity Certificates
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.). -
Page 72: Service Journal
Service Journal Action 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. -
Page 73: After First 8 Hours
SERVICE JOURNAL After the First 5-8 Hours 1. Change engine oil. English... -
Page 74: 25-Hour Service
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. -
Page 75: 50-Hour Service
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). Change engine oil. 4. Lubricate according to lubrication chart. 5. Check/adjust the parking brake. English... -
Page 76: 100-Hour Service
Action 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. Check V-belts. Check tighten caster wheel axle bolts (every 200 hours). -
Page 77: 300-Hour Service
SERVICE JOURNAL 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. -
Page 78: At Least Once Each Year
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. - Page 79 SERVICE JOURNAL Action Date, mtr reading, stamp, sign English...
- Page 80 Part No. 539 118101 R01 (08/14/07)