Dixon 27 KOH/968999588 Operator`s manual

™
GRIZZLY SERIES
™
BLACK BEAR
®
ZTR
ZTR®
Operator’s Manual
GRIZZLY 52, 27 KOH/968999588
GRIZZLY 60, 27 KOH/968999590
GRIZZLY 60, 30 KOH/968999591
GRIZZLY 72, 27 KOH/968999592
Please read the operator’s manual carefully
and make sure you understand the
instructions before using the unit.
English
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. It contains valuable
information that is necessary for the safe operation of the machine.
Observe all safety rules and become completely familiar with the
controls.
The information contained in this manual applies to all Dixon
Grizzly™ ZTR® mowers.
See your authorized Dixon dealer for warranty service, parts and
repairs or to answer any questions you may have about your new
Dixon ZTR.
3
4
TABLE OF CONTENTS
GENERAL OPERATION .................................................................. 8-9
SLOPE OPERATION ................................................................... 10-11
ROLL OVER PROTECTION SYSTEM (ROPS) .......................... 12-13
FIRE HAZARDS .......................................................................... 14-15
CHILDREN, BYSTANDERS AND PETS .......................................... 16
SERVICE .......................................................................................... 17
TECHNICAL DATA ...................................................................... 19-22
CONTROLS ................................................................................. 24-27
CONTROL LEVERS ........................................................... 24
PARK BRAKE .................................................................... 25
BLADE DRIVE .................................................................... 26
CHOKE AND THROTTLE CONTROL LEVER ................... 26
MOWER DECK CUT HEIGHT LIFT LEVER ...................... 27
OPERATION INSTRUCTIONS ........................................................ 28STARTING .................................................................... 22-29
TESTING OF SAFETY INTERLOCK SYSTEMS .......... 30-31
MOWING WITH A MULCHING ATTACHMENT ............ 32-33
GRASS CATCHER ATTACHMENT .............................. 34-35
SIDE DISCHARGE ............................................................. 36
GRASS HEIGHT ................................................................ 37
TOWING ............................................................................. 38
UNLOCK TRANSMISSION ................................................ 38
CARE AND MAINTENANCE ....................................................... 39-47
MAINTENANCE SCHEDULE ............................................. 39
BLADES ............................................................................. 40
BELTS ................................................................................ 41
BATTERY ........................................................................... 42
TIRES ................................................................................. 43
LUBRICATION ................................................................... 43
CHANGING THE ENGINE OIL .......................................... 44
HYDROSTATIC TRANSMISSION ..................................... 45
SERVICE INTERVALS ....................................................... 45
MOWER DECK LEVELING PROCEDURE ........................ 46
CLEANING THE MOWER .................................................. 47
PARTS/SERVICE ............................................................................. 47
STANDARD SERVICE PARTS LIST ................................................ 48
TROUBLESHOOTING ................................................................. 49-50
GRIZZLY SERIES™
Part Number 539 114590R1
5
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
6
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.
WARNING
(highlighted in orange)
indicates a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
CAUTION
(highlighted in yellow)
indicates a potentially
hazardous situation which,
if not avoided, may result in minor
or moderate injury. It may also
be used to alert against
unsafe practices.
7
WARNING
!
WARNING
Failure to observe the following 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.
Clear the area of objects such as rocks, toys, wire, etc., that could
be picked up and thrown by the blade.
Be sure the area is clear of bystanders before mowing. Stop mower
if anyone enters the area.
Never direct discharged material toward anyone. Avoid discharging
against a wall or obstruction. Material may ricochet back toward the
operator. Stop the blade(s) when crossing gravel surfaces.
Do not operate the mower without either the entire grass catcher or
the deflector in place. This will decrease the possibility of injury
from objects being thrown by the mower blades.
Never carry passengers.
Do not mow in reverse unless absolutely necessary. Always look
down and behind before and while backing.
Never leave a running mower unattended. Always turn off blades,
set park brake, stop engine and remove key before dismounting.
Turn 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 while blades or impeller are still
running.
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects or other reproductive harm.
8
WARNING
!
WARNING
Failure to observe the following instructions
could result in serious injury or death.
GENERAL OPERATION (continued)
To avoid personal injury from accidental clutch engagement, 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.
Slow down before turning to reduce the risk of tip-over.
Watch for traffic when operating near or crossing roadways.
Use extra care when loading or unloading the mower into a trailer
or truck. Push, do not ride the mower when loading and unloading.
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 ability to operate the riding
mower safely enough to protect themselves and others from
serious injury.
To protect against possible tip-over, follow the manufacturer’s
recommendation for wheel weights and counterweights.
Maintain or replace safety and instruction labels as needed.
9
WARNING
!
WARNING Failure to observe the following instructions
could result in serious injury or death.
SLOPE OPERATION
Slopes are a major factor related to loss-of-control and tipover accidents, which can result in severe injury or death.
All slopes require extra caution. If you feel unsure on any
slope, do not mow it!
DO
Mow up and down the slope with your Dixon ZTR — never across.
This will decrease the risk of tip-over.
Remove obstacles such as rocks, tree limbs, wires and other
foreign objects that can be thrown by mower blades.
Watch for holes, ruts, roots and bumps, and uneven terrain that
could overturn the mower. Tall grass can hide such obstacles.
Use slow speed. Tires may lose traction on slopes even though the
brakes are functioning properly.
Avoid starting or stopping on a slope. If tires lose traction,
disengage the blades and proceed slowly down the slope.
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.
If front wheels lift off the ground, pull levers back to stabilize the
mower. Discontinue mowing the slope!
10
WARNING
!
WARNING
Failure to observe the following 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 tipover.
Do not mow near drop-offs, ditches, or embankments. Unstable
ground may cause loss of control.
Do not mow on wet grass. Reduced traction could cause sliding.
Do not try to stabilize the mower by putting your foot on the ground.
Do not use grass catcher or other attachments on steep slopes.
The added weight may change the stability of the mower, creating
the potential for tip-over.
11
WARNING
!
WARNING
Failure to observe the following instructions
could result in serious injury or death.
ROLL OVER PROTECTION SYSTEM (ROPS)
The ROPS increases the basic weight of the unit by 42 Ibs/19 kg.
The ROPS on the US units are standard, on the European unit the
ROP is an accessory.
The ROP’s capability may be impaired by structural damage if
overtumed or alterations are made. Do not make changes to the
structure and if any damage occurs, replace the entire ROPS unit.
• Do not use ROPS as a lifting, attaching or anchoring point.
• Do not use ROPS for wrecking or towing.
• Do not exceed maximum gross vehicle weight of 2822 Ibs.
(1283 kg).
• Securely fasten your seat belt if the unit has a ROPS.
• Where possible, avoid operating the mower near ditches,
embankments or holes.
• Reduce speed when turning, crossing slopes and on rough,
slick or muddy surfaces.
• Stay off slopes too steep for safe operation.
• Watch where you are going, especially at row ends, on roads
and around trees.
• Do not permit others to ride.
12
WARNING
ROLL OVER PROTECTION SYSTEM (ROPS)
(continued)
• Operate the mower smoothly - no jerky turns, starts or stops.
• When mower is stopped, set brakes securely and use park
brake.
• If any part of ROPS is damaged, the entire ROPS must be
replaced.
• Check all bolts, including seat belt, for correct torque before
each use.
• Check ROPS structure for damage before each use.
• ROPS bar is NOT intended for use in sub zero temperatures.
Owner/operator responsibilities
• Read and observe the safety rules.
• Follow a regular schedule in maintaining, caring for and using
your mower.
• Follow the instructions under “Maintenance” and “Storage”
sections of this owner’s manual.
13
WARNING
!
WARNING
Failure to observe the following instructions
could result in serious injury or death.
FIRE HAZARDS
Use extra care when handling gasoline 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.
To reduce fire hazard, keep mower free of grass, leaves and other
debris buildup.
If gasoline is spilled, do not attempt to start the engine. Move
mower away from the area of the spill. Do not create any source of
ignition until gas vapors have dissipated. Wipe up spilled fuel and
dispose of waste properly.
If fuel is spilled on clothing, change clothing immediately.
Before storing, allow mower to cool. Clean fuel and oil spillage.
Never store the mower or fuel container inside a building where
there is an open flame.
14
WARNING
!
WARNING
Failure to observe the following 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. This decreases the chance of sparking and fire.
Use care when backing to avoid pushing the grass bags into the
frame or “hot” exhaust muffler of the engine. Fire could result.
To prevent fire and explosion caused by static electricity:
Never fill containers inside a vehicle or on a truck or trailer
bed with a plastic liner. Always place containers on the
ground away from your vehicle before filling.
When practical, remove fuel powered equipment from the
truck or trailer and refuel it on the ground. If this is not
possible, refuel such equipment on a trailer with a portable
container, rather than from a fuel dispenser nozzle.
If a fuel dispenser nozzle must be used, keep the nozzle in
contact with the rim of the fuel tank or container opening at all
times until fueling is complete. Do not use a nozzle lock-open
device.
15
WARNING
!
WARNING
Failure to observe the following instructions
could result in serious injury or death.
CHILDREN, BYSTANDERS AND PETS
Tragic accidents can occur if the operator is not alert to the
presence of children, bystanders and pets.
Children are attracted to lawn mowers
and the mowing activity.
NEVER assume children, bystanders and pets
will stay where they were last seen.
Be alert to avoid accidents.
Keep bystanders and pets out of the mowing area and keep
children under the watchful care of another responsible adult.
Be alert and turn mower off if bystanders, children or pets enter the
area.
Before and during backing look BEHIND and DOWN for small
children.
Never carry children as passengers. They may fall off and be
seriously injured or interfere with safe mower operation.
Never allow children to operate the mower.
Use extra care when approaching blind corners, shrubs, trees, or
other objects that may obscure vision.
16
WARNING
!
WARNING
Failure to observe the following 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. Check their proper operation
regularly.
Stop and inspect the equipment if you strike an object. Repair, if
necessary, before restarting.
Never make adjustments or repairs with the engine running unless
otherwise specified.
Grass catcher components are subject to wear, damage and
deterioration that could expose moving parts or allow objects to be
thrown. Frequently check components. Replace with original
equipment parts when necessary.
When servicing blades, wrap blades or wear gloves, and use extra
caution.
Batteries contain sulfuric acid. To prevent burns, avoid contact with
skin, eyes and clothing.
17
DIXON® ZTR® PRO SERIES COMMERCIAL / RESIDENTIAL WARRANTY POLICY
Black BearTM, Kodiak®, Mountain Kodiak®, Kodiak® Diesel, Grizzly™ & SilverTip™
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 REPAIR OF PARTS INCLUDING LABOR COSTS.
THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS AND LIMITATIONS:
1. COMMERCIAL WARRANTY (use other than, or in addition to, mowing at owner’s primary place of
residence):
a. First two years - 100% parts and labor subject to the conditions and limitations described herein with
the exception of non-covered items specified below.
b. 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.
c. Attachments marketed through or approved by Dixon are warranted for one year parts and labor in
commercial use applications.
d. Pro Series Models are not subject to hour meter restrictions.
e. Warranty applies to new mowers.
2. RESIDENTIAL WARRANTY (used only at owner’s primary place of residence):
a. Three years - 100% parts and labor subject to the conditions and limitations described herein for a
period of three years from date of purchase by the original owner.
b. Attachments marketed through or approved by Dixon are warranted for two years parts and labor in
residential useapplications.
c. Warranty applies to new mowers.
3. Lifetime warranty on all frames and leading edge of all fabricated (welded) decks.
4. All Dixon® warranty must be accomplished by authorized Dixon® dealers and in accordance with Dixon®
warranty policy and allowances.
All warranty claims must be submitted to Dixon for approval.
5. Warranty labor reimbursement to dealers based on published Dixon® flat rate schedule.
6. Warranty does not apply to damage in transit or incidents of misuse, negligence, accidents, or alteration.
The use of parts or components other than those supplied by Dixon VOIDS ALL WARRANTY.
7. Battery warranty is limited to 1 year from mower manufacture date.
8. The following items are not covered by this warranty policy:
a. Routine maintenance or adjustments to include any oils, filters or other fluids used.
b. Belts, blades, tires and cosmetic appearance (paint, seat fade, etc.)
c. Pick up and delivery charges for transportation of mower to and from an authorized Dixon® dealer’s
place of business.
d. Engines. These are covered under a separate warranty by each individual engine manufacturer.
Consult engine manual for warranty details.
e. Any costs or expense of providing substitute equipment while repair work is being performed on a
warranted mower.
9. THERE IS NO OTHER EXPRESS WARRANTY. TO THE EXTENT PERMITTED BY LAW, ALL IMPLIED
WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE ARE EXCLUDED; OTHERWISE, ALL SUCH IMPLIED WARRANTIES ARE LIMITED TO THE
SAME DURATION AND REMEDIES AS THE EXPRESS WARRANTY. ALL LIABILITIES FOR
CONSEQUENTIAL DAMAGES UNDER ANY EXPRESS OR IMPLIED WARRANTY ARE EXCLUDED.
18
SPECIFICATIONS
GRIZZLY™ 52 Model 968999588
Chassis:
10 gauge sides with 7 gauge cross members
Mower Deck:
Made of 11 gauge fabricated welded construction
with external reinforcement ribs. Three blades
combine for a 52" (132 cm) cut width. Cut height
approximately 1½" (38mm) to 6" (152 mm) via 18
position lift handle with foot assist.
Blade Drive:
Electric clutch
Drive System:
Each rear wheel is independently driven by a
Hydro Gear hydrostatic drive 10cc pump and TL
240 wheel motor.
Engine:
27 HP Kohler, twin cylinder, overhead valve, air
cooled, gasoline, full pressure lube with oil filter.
Starting
System:
Electric-key switch operation with safety interlocks
on park brake and blade drive clutch.
Tires:
Front
Rear
Capacities:
Fuel
Hydrostat
Fluid tank
13 x 6.5 x 6 smooth tread
23 X 9.5 X 12 Turf pneumatic
Engine Oil
Dimensions:
Width
Height
Length
Weight
11 gallon (42 liters) approximately
2 qts (1.8 liters) with inline 25 micron
filter and 15W50 synthetic
hydrostatic oil
2 qts. (1.8 liters) SAE 10W30 oil
with filter
50" (127 cm)
48" (122 cm)
84" (214 cm)
1140 lbs. (517 kg)
Additional information may be provided elsewhere in this manual.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
19
SPECIFICATIONS
GRIZZLY™ 60 Model 968999590
Chassis:
10 gauge sides with 7 gauge cross members
Mower Deck:
Made of 11 gauge fabricated welded construction
with external reinforcement ribs. Three blades
combine for a 60" (152 cm) cut width. Cut height
approximately 1½" (38mm) to 6" (152 mm) via 18
position lift handle with foot assist.
Blade Drive:
Electric clutch
Drive System:
Each rear wheel is independently driven by a
Hydro Gear hydrostatic drive 10cc pump and
TL 240 wheel motor.
Engine:
27 HP Kohler, twin cylinder, overhead valve, air
cooled, gasoline, full pressure lube with oil filter.
Starting
System:
Electric-key switch operation with safety interlocks
on park brake and blade drive clutch.
Tires:
Front
Rear
Capacities:
Fuel
Hydrostat
Fluid tank
13 x 6.5 x 6 smooth tread
24 X 12 X 12 Turf Master
Engine Oil
Dimensions:
Width
Height
Length
Weight
11 gallon (42 liters) approximately
2 qts (1.8 liters) with inline 25 micron
filter and 15W50 synthetic
hydrostatic oil
2 qts. (1.8 liters) SAE 10W30 oil
with filter
54" (137 cm)
48" (122 cm)
84" (214 cm)
1150 lbs. (522 kg)
Additional information may be provided elsewhere in this manual.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
20
SPECIFICATIONS
GRIZZLY™ 60 Model 968999591
Chassis:
10 gauge sides with 7 gauge cross members
Mower Deck:
Made of 11 gauge fabricated welded construction
with external reinforcement ribs. Three blades
combine for a 60" (152 cm) cut width. Cut height
approximately 1½" (38mm) to 6" (152 mm) via 17
position lift handlewith foot assist.
Blade Drive:
Electric clutch
Drive System:
Each rear wheel is independently driven by a
Hydro Gear hydrostatic drive 10cc pump and
TL 240 wheel motor.
Engine:
30 HP Kohler, twin cylinder, overhead valve, air
cooled, gasoline, full pressure lube with oil filter.
Starting
System:
Electric-key switch operation with safety interlocks
on park brake and blade drive clutch.
Tires:
Front
Rear
Capacities:
Fuel
Hydrostat
Fluid tank
13 x 6.5 x 6 smooth tread
24 X 12 X 12 Turf Master
Engine Oil
Dimensions:
Width
Height
Length
Weight
11 gallon (42 liters) approximately
2 qts (1.8 liters) with inline 25 micron
filter and 15W50 synthetic
hydrostatic oil
2 qts. (1.8 liters) SAE 10W30 oil
with filter
54" (137 cm)
48" (122 cm)
84" (214 cm)
1150 lbs. (522 kg)
Additional information may be provided elsewhere in this manual.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
21
SPECIFICATIONS
GRIZZLY™ 72 Model 968999592
Chassis:
10 gauge sides with 7 gauge cross members
Mower Deck:
Made of 11 gauge fabricated welded construction
with external reinforcement ribs. Three blades
combine for a 72" (183 cm) cut width. Cut height
approximately 1½" (38mm) to 6" (152 mm) via 17
position lift handle with foot assist.
Blade Drive:
Electric clutch
Drive System:
Each rear wheel is independently driven by a
Hydro Gear hydrostatic drive 10cc pump and
TL 240 wheel motor.
Engine:
30 HP Kohler, twin cylinder, overhead valve, air
cooled, gasoline, full pressure lube with oil filter.
Starting
System:
Electric-key switch operation with safety interlocks
on park brake and blade drive clutch.
Tires:
Front
Rear
Capacities:
Fuel
Hydrostat
Fluid tank
13 x 6.5 x 6 smooth tread
24 X 12 X 12 Turf Master
Engine Oil
Dimensions:
Width
Height
Length
Weight
11 gallon (42 liters) approximately
2 qts (1.8 liters) with inline 25 micron
filter and 15W50 synthetic
hydrostatic oil
2 qts. (1.8 liters) SAE 10W30 oil
with filter
52" (132 cm)
48" (122 cm)
86" (218 cm)
1200 lbs. (544 kg)
Additional information may be provided elsewhere in this manual.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
22
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.
Seat Slide
Adjuster
23
CONTROLS
CONTROL LEVERS
For access to the seat, move control levers to neutral position and
swing them outward.
NEUTRAL
SLOW
FORWARD
FAST
FORWARD
90o
RIGHT
SLOW
REVERSE
TURN
Left Turn Opposite
TO GO FORWARD
• From neutral position, gently push control levers forward.
• To increase speed, move levers further forward.
TO GO BACKWARDS
• From neutral position, gently pull control levers
toward you.
TURNING
• Turning is controlled by moving one control lever slightly
forward or rearward of the other.
• To turn left, move left lever rearward of the right lever.
• To turn right, move right lever rearward of the left lever.
• To turn on mower’s own axis (zero turning radius), stop and
move one lever to reverse position and the other to forward
position.
BRAKING
• To brake mower, move both levers in direction opposite of
travel.
NOTE: The pressure required to operate the mower is very light.
24
CONTROLS
PARK BRAKE
The park 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
park brake is engaged while the control levers are in
the drive position.
!
CAUTION
Engage park brake before
starting engine.
TO SET PARK BRAKE
The hand-operated park brake is located on the left
hand side.
•To engage brake, pull lever up (to the rear).
•To release brake, move lever forward (down).
NOTE: Always set park brake before dismounting.
Release park brake before moving mower.
25
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.
CHOKE AND THROTTLE CONTROL LEVER
•
Throttle control for engine speed.
•
Choke for engine starting.
•
Throttle control should be set to
MAXIMUM or wide open setting to
insure adequate cooling of the engine
and to maintain mower deck blade
speed while mowing.
26
STOP
BLADES
Located on control panel to operator’s right.
ON
•
OPERATION INSTRUCTIONS
MOWER DECK CUT HEIGHT LIFT LEVER
The lifting lever is used to place the mower deck in the transport
position or one of the 18 different cutting heights.
The cutting height is set by placing a peg in the hole for the desired
cutting height and the peg is then locked on the inside with the
supplied pin.
1. To set the deck in the transport position, squeeze the underpin
upwards to the lift handle and pull
the lever backward to the locked
position (raised).
2. To set the deck for
mowing, select the desired
mowing height and place
the lock pin into the
matching hole. Secure on
the inside with hairpin
cotter. Squeeze the
underpin upwards to the lift
handle and push the lever
forward to the lock pin.
Release the lift handle.
3. The lift lever can also be
used to temporarily adjust the cutting
height, such as when passing a minor bump
in the lawn.
27
OPERATION INSTRUCTIONS
The safe and successful operation of the GRIZZLY will depend on
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 without complete knowledge of all controls
and their functions to operate the mower.
During initial operation, “learning to drive”, set throttle at slow
speed.
Sound judgement by the operator will prevent accidents.
BEFORE OPERATING MOWER
1. Read engine manufacturer’s operating and maintenance
instructions.
2. Read and observe all safety instructions on your mower and in
the manual.
3. Check engine oil.
4. Check fuel cap to be sure it is in place.
5. Be sure park brake is on.
6. Be sure mower blade drive is off.
7. Know how to stop engine. (Turn key to OFF position).
28
OPERATION INSTRUCTIONS
!
CAUTION
Failure to observe the following instructions
could result in personal injury.
STARTING INSTRUCTIONS
1. Park brake must be on, control levers in outward position with
the operator sitting on the seat, and blade drive disengaged.
2. Position throttle to desired speed setting. If engine is cold,
position choke lever in the ON position.
NOTE: Engine may require partial choke setting to start even if
the engine has been operated for a period of time.
3. Insert ignition key and turn to START position. When engine
starts, release ignition key. Key will return to RUN position.
4. Return choke to OFF position, if applicable.
5. Move throttle to maximum speed position.
6. Release park brake.
7. Swing levers inward.
8. Operate mower per CONTROL instructions on Page 25.
!
CAUTION
Note:
Do not operate the engine in an enclosed area
due to the harmful exhaust gas produced.
When mowing with blades engaged, set throttle control
to the MAXIMUM or wide open setting to insure adequate
cooling of the engine and to maintain mower deck blade
speed.
29
OPERATION INSTRUCTIONS
TESTING OF SAFETY INTERLOCK SYSTEMS
!
WARNING
Failure to observe the following instructions
could result in serious injury or death.
The following tests should be performed at the start of each
mowing day.
PARK BRAKE SWITCH TEST
1.
2.
3.
4.
Swing control levers to outward position.
Disengage blade drive.
Put park brake in OFF position.
Turn ignition switch to START.
Engine should not turn over or attempt to start.
CONTROL LEVER SWITCH TEST
1.
2.
3.
4.
Disengage blade drive.
Put park brake in ON position.
Swing control levers inward.
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.
30
OPERATION INSTRUCTIONS
TESTING OF SAFETY INTERLOCK SYSTEMS
!
WARNING
Failure to observe the following instructions
could result in serious injury or death.
The following tests should be performed at the start of each
mowing day.
BLADE DRIVE SWITCH TEST
1.
2.
3.
4.
Put park brake in ON position.
Swing control levers to outward position.
Engage blade drive.
Turn ignition switch to START.
Engine should not turn over or attempt to start.
SEAT SWITCH TEST
1. In a SAFE AREA away from bystanders, start the engine.
2. Leave control levers in outward position and put park brake ON
position.
3. Engage blade drive.
4. Raise slightly off seat. Engine should stop!
NOTE: If any safety check fails, do not operate the mower until
the system has been checked and repaired by an
authorized Dixon dealer.
31
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.
In order to achieve the best results, please read and follow the
mulching tips listed below:
1. Read and follow the installation instructions that are included
with your mulcher.
2. Set the engine speed control to the wide open or full setting.
3. Place the mower deck cut height selector in either the top or
second notch. Never cut more than ¾" (19 mm) to 1" (25mm)
off the grass at any one time. Attempting to cut more grass will
result in the deck plugging and cause the engine to stall.
4. It may be necessary to cut the lawn twice to achieve acceptable
mulching performance especially on first cuttings or if the lawn
is heavily fertilized.
5. Do not attempt to cut grass when it is wet. Mulching
performance will be very poor in wet grass conditions.
6. Maintain sharp blades throughout the cutting season. This is
very important. Optimal mulching performance cannot be
obtained with a dull or nicked blade.
32
OPERATION INSTRUCTIONS
MOWING WITH A MULCHING ATTACHMENT
(continued)
7. Keep the underside of the mower deck clean. Remove all
grass and dirt buildup 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.
8. Alternate mower direction. This will evenly disperse the
mulched grass clippings over the lawn for even fertilization.
If the mulching quality of the mower does not seem
to be satisfactory, try one or more of the following
tips:
•
•
•
•
•
•
Raise the height-of-cut setting on your mower.
Cut grass more frequently.
Operate the mower at a slower ground speed.
Overlap cutting swaths instead of cutting a full swath with each
pass.
Mow across the marginal areas a second time.
CUT HIGH - MOW OFTEN!
33
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.
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 setting.
3. Do not attempt to cut grass when it is wet. Wet grass will clog
both the underside of the deck and the attachment chutes.
Empty bags often to prevent plugging.
4. If the grass is tall, place the mower deck cut height selector in
the top or second notch. “Initially” overlap cutting swaths
instead of a full swath with each pass.
5. Keep the underside of the mower deck clean. Frequent removal
of dried grass and dirt will greatly assist in bagging of the
clippings. 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.
6. Operate the mower at a slower ground speed than when
mowing without a grass catching attachment.
34
OPERATION INSTRUCTIONS
MOWING WITH A
GRASS CATCHER ATTACHMENT (continued)
7. Maintain sharp blades throughout the cutting season. Some
grass catching attachments require a “high-lift” blade. See your
dealer for advice on the type of blade(s) needed for your
mower.
8. Some mowing applications or 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. Ensure mower is equipped with an approved, dealer-installed
roll-over protection and seat belt kit.
!
WARNING
Failure to observe the following instructions
could result in serious injury or death.
• Watch for low hanging branches or other obstacles that might
hit the catcher top while turning or backing the mower.
• Use care when backing to avoid pushing the grass bags into
the frame or “hot” exhaust muffler of the engine. Fire could
result.
• Disengage blade and stop engine prior to clearing grass from
either the discharge chute or grass catcher components.
• Do not operate the mower with the grass catching attachment
partially removed. Operator or bystanders could be injured by
thrown objects.
• Keep all attachment bolts tight.
• Important: Do not leave clippings in the bags while the mower is
stored. Damp grass clippings are a fire hazard if left in the bag.
35
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
To avoid personal injury, 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.
3. 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.
4. Keep the underside of the mower deck clean. Frequent removal
of dried grass and dirt will allow the clippings to discharge
correctly. Never, under any circumstances, place your
hands or feet under the mower deck or in the chute while
blades or impeller are still turning.
5. Maintain sharp blade(s) throughout the cutting season.
36
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.
Keep the underside of the mower deck clean.
Maintain sharp blades throughout the cutting season.
As a rule of thumb, never cut off more than one third of the total
grass blade length. Correct mowing height can reduce weeds and
disease by 50% to 80%.
The following grass cut heights are based on adequate moisture
conditions and normal thatch buildup in a healthy lawn. Some
locations and applications may require slightly different cut heights.
If in doubt, consult your local lawn professional for assistance.
Grass Types
Best Cut Heights
Bermudagrass
1 - 2"
(25-51 mm)
Bluegrass
2 - 3"
(51-76 mm)
Buffalograss
1½ -3" (38-76 mm)
Ryegrass
2 - 3"
Tall Fescue
3-3½" (76-89 mm)
Zoysiagrass
1 - 3"
37
(51-76 mm)
(25-76 mm)
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 (113 kg) or less with this mower.
To Free Wheel Machine
(Unlock Transmission)
When pushing or pulling the mower, be sure to engage the hydro
release levers. Always turn off engine before engaging or
disengaging the hydro release (free wheel) lever. Never attempt to
move the lever with the engine running.
1. Raise the deck to the
highest cutting position.
2. The hydro release valves
are located behind the seat,
on the front side of the
hydro pumps.
Freewheel
3. To access the release
Valve
valves, lift the seat frame
assembly.
4. With a 5/8" wrench, rotate
bolt counter-clockwise two
full turns to disengage
pump.
5. Repeat procedure for
opposite pump.
6. To engage, rotate each
pump bolt clockwise until bolt is snug.
NOTE: Before pushing or towing tractor, transmission must be
unlocked and park brake released. The tractor should
never be pulled at more than 2 miles per hour (3.2 km/h)
or for distances over ¼ mile (.402 km). Trailer the unit for
distances over ¼ mile.
38
CARE AND MAINTENANCE
!
CAUTION
Failure to observe the following instructions
could result in personal injury.
Before performing any maintenance, turn off engine,
allow to cool and 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
MAINTENANCE SCHEDULE
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Adjust traction drive idler ................................. after 5 hours break-in
Check deck serpentine belt ........................... after 20 hours break-in
Check crankcase oil level ........................................ before each use
Clean grass from hydrostat fans .............................. before each use
Clean grass, debris from muffler & manifold area .... before each use
Clean grass under deck .............................................. after each use
Check tire pressure .................................................... every 10 hours
Inspect blades for sharpness ..................................... every 10 hours
Check hydrostatic transmission fluid .......................... every 25 hours
Clean air filter element ............................................... every 25 hours
Check traction drive idler adjustment ......................... every 50 hours
Grease all zerks ......................................................... every 50 hours
Check all belts ........................................................... every 50 hours
Change engine crankcase oil & filter ................. 5 hours break-in and
................................................................................... every 50 hours
Change engine oil filter .............................................. every 50 hours
Replace air filter element ...................... annually or every 100 hours
Replace spark plugs ................................................ every 100 hours
Change hydrostat fluid & fluid filter ................ 100 hours break-in and
................................................................................. every 500 hours
39
CARE AND 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.
CUTTER BLADE MAINTENANCE
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.
3. Loosen blade bolt and remove blade.
4. When replacing blade, tighten blade bolt
securely. Tighten blade bolt to 60 ft.
lbs. (81Nm)
Blades should be discarded when worn excessively.
New blade
When notch starts,
discard blade
40
DANGEROUS!
Do not use blade
in this condition!
CARE AND MAINTENANCE
BELTS
Check belts every 100 hours. Replace any belts showing signs of
severe cracking or large nicks. Belts are not adjustable, replace if
they begin to slip from wear.
BELT TENSION
Engine to Mower Deck Belt
To adjust tension of the mower deck drive belt, turn adjuster nut on
threaded eyebolt. Turning nut clockwise will make the belt tighter.
Turning nut counterclockwise will loosen the belt.
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.
41
CARE AND MAINTENANCE
BATTERY
This is a maintenance-free battery and the fluid level cannot be
checked. Charge battery if required.
OFF SEASON BATTERY STORAGE
•
•
DO NOT remove battery from mower.
Clean top of battery and terminals with baking soda
and water.
Identify each cable so they can be reconnected to the correct
terminal.
Disconnect cables from terminals. ALWAYS disconnect ground
cable first and reconnect last.
Charge battery.
•
•
•
!
CAUTION
Battery contains sulfuric acid electrolyte that is poisonous and corrosive.
42
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
15 PSI
15 PSI
(103 kPa)
(103 kPa)
Lug nuts or lug bolts should be checked regularly for tightness.
LUBRICATION
CHASSIS:
(13) grease zerks
LOCATIONS:
(4) front wheel casters
(3) mower deck hubs
(4) decklift shafts
(2) brake arms
SERVICE INTERVALS:
Every 50 hours of operation or once
per season
RECOMMENDED
GREASE:
Name brand wheel bearing
or multipurpose grease
(3 pumps each)
43
CARE AND MAINTENANCE
!
CAUTION
HOT oil may cause burns. Allow engine to
cool before draining oil.
CHANGING THE ENGINE OIL
The EZ Drain oil plug is located on the left side of the engine
crankcase.
1. Uncap the end of the drain plug and install the oil drain hose.
2. Place a suitable container
under the drain hose.
3. To drain, turn the drain plug
Cap
counter-clockwise to unlatch.
Pull the plug outward until it
stops.
3. After engine is drained,
remove hose, recap end.
Latch
Push in and turn the plug
clockwise to relatch.
4. Change oil filter.
5. Fill with oil (see steps below).
NOTE: Refer to engine manufacturer’s recommendations for
frequency of oil changes.
OIL FILL
1. Clean any spilled oil from engine and chassis.
2. Refill engine with type, and quantity of oil recommended by the
engine manufacturer in engine literature.
NOTE: Engine oil changes on the Grizzly will require replacement
of the oil filter. These filters may be available from your
local Dixon Dealer.
44
CARE AND MAINTENANCE
HYDROSTATIC TRANSMISSION FLUID
AND FILTER SERVICE
Dirt or water in fluid can ruin the hydrostatic transmissions.
SERVICE INTERVALS
1. Initial filter service - 100 hours
2. Every 300 hours or once a year thereafter.
MAINTENANCE PROCEDURE
Check the fluid level in hydrostatic transmission fluid reservoir daily.
Clean the fluid reservoir cap and the
area around it prior to removal.
Check the fluid level. Fluid should
be approximately ¾" to 1" (19 - 25
mm) below top of fluid tank baffle.
Replenish with full synthetic 15W-50
as needed. DO NOT OVERFILL.
When checking the fluid level, be
very careful to keep the reservoir
clean. Check connections, hoses,
and tubes for damage or leaks.
Replace or repair if doubtful.
Changing Oil and Filters
Oil and filter changes should be carried out by an authorized
service workshop due to the risk of impurities enter the system.
45
CARE AND MAINTENANCE
MOWER DECK LEVELING PROCEDURE
There are four (4) eyebolts that will control the attitude or pitch of
the mower deck. The deck should be level or pitched slightly
higher in rear.
1. Place the mower on a smooth level surface with front casters
positioned towards deck. Check tire pressures to insure the
mower has a correct stance. Inflate tires as required:
Front
15 lbs (103 kPa)
Rear:
15 lbs (103 kPa)
NOTE: To insure accuracy of leveling procedure, mower deck
drive belt must be installed prior to leveling deck.
2. Wear heavy gloves. Turn each outer blade tip to align with the
deck or in a side-to-side manner.
3. Measure from the floor surface up to the bottom of the blade tip
on the discharge side of the mower. Retain this measurement.
Move to the opposite side and check to see if that
measurement is the same. If adjustment is required, turn nut
on one or both of the front eyebolts until both measurements
are equal.
4. Turn each outer blade tip to align with the deck in a front to
rear manner.
5. Measure from the floor surface up to the bottom of the blade
tips at both the front and rear of the blades. Rear of blade tips
should be 1/8" to ¼" higher than the front of blade tips. If
adjustment is required, turn nut on one or both of the rear
eyebolts until both measurements are equal.
NOTE: This will place the mower deck in a base measurement
position. Additional adjustment may be required to
achieve desired cut for the type of grass or conditions
involved.
46
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 disperse any water that may have accumulated in
bearings, pulleys or fans.
Note:
Allow mower to cool before washing. If bearings are hot,
they will draw moisture inside as they dry and cause
corrosion.
SERIAL NUMBERS
The serial number is located on frame at rear of engine.
WARRANTY
Refer to warranty information.
PARTS/SERVICE
See your Dixon dealer for replacement parts, warranty or service.
47
STANDARD SERVICE PARTS LIST
BLADES
52" Deck
* Hi Lift Fusion P/N 539 117911
Gator Fusion P/N 539 118035
Hi-Lift
P/N 539 118272
Lo-Lift Fusion P/N 539 117973
60" Deck
* Hi Lift Fusion P/N 539 119840
Spr Hi-Lift Fus P/N 539 119801
Gator Fusion P/N 539 119875
Lo-Lift Fusion P/N 539 119873
Hi-Lift
P/N 539 119871
Standard Lift P/N 539 119872
72" Deck
* Hi Lift Fusion
Spr Hi-Lift Fus
Std Lift Fusion
Hi-Lift
Std Lift
P/N 539 119841
P/N 539 119802
P/N 539 119878
P/N 539 119876
P/N 539 119877
* Factory installed
BELTS
52" Deck
Engine to Mower Deck
Engine to Hydros
P/N 539 114550
P/N 539 104334
60" Deck
Engine to Mower Deck
Engine to Hydros
P/N 539 112529
P/N 539 104334
72" Deck
Engine to Mower Deck
Engine to Hydros
P/N 539 114552
P/N 539 104334
ENGINE AIR AND OIL FILTERS
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.
48
TROUBLESHOOTING
1. ENGINE WON’T TURN OVER
Mower blades engaged - - - - - - - - - - - - - - - - - - - - disengage blades
Park brake not on - - - - - - - - - - - - - - - - - - - - - - - - engage park brake
Dead battery - - - - - - - - - - - - - - - - - - - - - - - - - - - charge or replace
Solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
Ignition switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
Starter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
2. ENGINE WILL TURN OVER BUT WON’T START
No fuel - - - - - - - - - - - - - - - - refuel and/or clean or replace fuel filters
3. HARD TO START ENGINE
Fuel line clogged - - - - - - - - - - - - - clean fuel line and check fuel filter
Faulty fuel pump - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
4. ENGINE STARTS BUT CUTS OUT
Water in fuel - - - - - - - - - - - - - - - drain old fuel-replace with new fuel
Clogged fuel line - - - - - - - - - - - - - - - - - - - - - - - - - - check fuel filter
Fuel tank vent plugged - - - - - - - - - - - - - - - - - - - - - - - clean fuel vent
Faulty fuel pump - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
5. ENGINE OVERHEATED
Air intake screen or fins clogged - - - - - - clean intake screen and fins
Oil level too low or too high - - - - - - - - - - - - - - - - - - - - adjust oil level
Running engine too slow - - - - - - - - - - - - - - - - - - - - run engine faster
49
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 bypass may be engaged - - - - disengage (see page 38)
7. MOWER LOSES POWER OR TRANSMISSION OVERHEATS
Engine air filter - - - - - - - - - - - - - - - - - - - - - - - - - - - clean or replace
Transmission damage - - - - - - - - - - - - - - - - - - - - - - consult dealer
8. ENGINE STALLS WHEN BLADES ARE ENGAGED
Operator not on seat - - - - - - - - - - - - - - - - - - - - - - - - - - - sit on seat
Faulty interlock system - - - - - - - - - - - - - - - - - - - - - - consult dealer
Faulty blade spindle bearing - - - - - - - - - - - - - - - - - - consult dealer
Deck drive belt not properly routed - - - - - - - - - - - - - - - - - - - reroute
Blades blocked by foreign material - - - - - - - - - - - - clean under deck
9. DRIVE SYSTEM
Mower pulls to side - - - - - - - - - - - - check tire inflation/consult dealer
Mower creeps in neutral - - - - - - - - - - - - - - - - - - - - - consult dealer
Low on power - - - - - - - - - - - - - - - - - - - - - - - - - check belt tension
10. CUT QUALITY
Cut uneven left to right - - - - - - - - - - - - check tire inflation/level deck
Ends of grass blades are ragged - - - - - - - - - - - - - - sharpen blades
Poor dispersal of grass - - - - - - - - - - clean deck/check for loose belt
Skips in spots - - - - - - - - - - check for loose belt/slow ground speed
50
OWNER’S INFORMATION
Date of Purchase ________________________________
Mower Model Number _____________________________
Mower Serial Number _____________________________
Purchased From ________________________________
________________________________
________________________________
DATE OIL CHANGED
____________________
DATE ENGINE TUNED
_____________________
____________________
_____________________
____________________
_____________________
____________________
_____________________
____________________
_____________________
____________________
_____________________
____________________
_____________________
Dixon ~401 North Commerce Street~Beatrice, NE~68310 ~402-223-1000~Fax 402-223-1053
Dixon and ZTR
are registered trademarks
of Dixon
!
WARNING
DIXON
401 Commerce Street
Beatrice, NE 68310
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects or other reproductive harm.
Grizzly Series
Part No. 539 114590R1