Operator`s manual | Dixon 44/968999538, 36 968999539, 42/968999546, 44/968999547 Lawn Mower User Manual

SPEEDZTR™ ZTR®
Safety Instructions
and
Operator’s Manual
Models ZTR ®44/968999538
ZTR®36/968999539
ZTR®42/968999546
ZTR®44/968999547
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 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
ZTR SpeedZTR™ mowers.
See your authorized Dixon dealer for warranty service, parts
and repairs or to answer questions you have about your new
Dixon ZTR.
TABLE OF CONTENTS
SAFETY AND WARNINGS ............................................................ 4-13
General Operation ............................................................. 6-7
Slope Operation ................................................................ 8-9
Fire Hazards .................................................................. 11-11
Children, Bystanders And Pets .......................................... 12
Service ............................................................................... 13
WARRANTY ..................................................................................... 14
SPECIFICATIONS ....................................................................... 15-18
CONTROLS ................................................................................. 21-24
Control Levers .................................................................... 19
Park Brake .......................................................................... 20
Transmission Drive System ............................................... 20
Blade Drive ......................................................................... 21
Throttle Control Lever ........................................................ 21
Choke Control .................................................................... 21
Circuit Breaker .................................................................... 21
Cut Height Lift Lever .......................................................... 22
OPERATION INSTRUCTIONS .................................................... 23-33
Starting ............................................................................... 24
Towing ................................................................................ 25
Testing Safety Systems ..................................................... 26
Mowing with Attachments ............................................. 28-31
Side discharge ................................................................... 32
Grass height ....................................................................... 33
CARE AND MAINTENANCE ....................................................... 34-45
Cutter blades ...................................................................... 35
Engine ................................................................................ 36
Battery ................................................................................ 36
Tires ................................................................................... 37
Lubrication ..................................................................... 37-38
Belts ................................................................................... 39
Neutral adjustment ............................................................. 40
Deck leveling ...................................................................... 41
Deck removal .................................................................... 42
Cleaning ............................................................................. 43
TROUBLESHOOTING ................................................................. 44-45
STANDARD SERVICE PARTS LIST ............................................... 46
SpeedZTR™ 36/42/44
Part Number 539 121042R1
SAFETY
!
WARNING
Riding lawn movers, 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
4
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.
5
WARNINGS
!
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.
In this operator’s manual, left and right, backward and
forward are used in relation to the machine’s normal driving
direction.
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.,
which 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.
6
WARNINGS
!
WARNING
Failure to observe the following instructions
could result in serious injury or death.
GENERAL OPERATION (continued)
Do not put hands or feet near rotating parts or under the
machine. Keep clear of the discharge opening at all times.
Disengage blade(s) 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.
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.
Always wear eye protection when operating machine.
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.
Follow the manufacturer’s recommendation for wheel weights
and counterweights.
7
WARNINGS
!
WARNING
Failure to observe the following instructions
could result in serious injury or death.
SLOPE OPERATION
Slopes are a major factor related to loss-ofcontrol and tip-over 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 across the slope with your Dixon ZTR -- never up or
down. 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!
8
WARNINGS
!
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 tip-over.
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 thus creating the potential for tip-over.
9
WARNINGS
!
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.
10
WARNINGS
!
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.
11
WARNINGS
!
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.
12
WARNINGS
!
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.
13
DIXON® ZTR® RESIDENTIAL WARRANTY POLICY
SpeedZTR™ & RAM 42 - Residential Mowers
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. RESIDENTIAL APPLICATION - (used only at owner’s primary place of residence):
a. Two Years - 100% parts and labor subject to the conditions and limitations described
herein for a period of two years from date of purchase by the original owner.
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 two years parts and
labor in residential use applications.
2.
NOT APPROVED FOR COMMERCIAL USE.
3.
Lifetime warranty on all frames and leading edge of all fabricated (welded) decks
(SPEEDZTR™ 36 & 44 only).
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 applies to new mowers.
6.
Warranty labor reimbursement to dealers based on published Dixon® flat rate schedule.
7.
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.
8. Battery warranty is limited to 1 year from mower manufacture date.
9. 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.
10. 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.
14
SPECIFICATIONS
SpeedZTR™ 36 Model 968999539
Chassis:
1½" x 2" rectangle tubular side frame
Body:
Body parts are made of steel
Mower Deck:
36" (91cm) 11 gauge fabricated construction with
reinforced ribs.
Blade Drive:
Electric clutch
Transmission:
Each rear wheel is independently driven by a
Hydro Gear EZT hydrostatic drive with cooling fan.
Engine:
16.5 HP Briggs & Stratton Intek, 4-cycle, single
cylinder, overhead valve, air-cooled, gasoline,
vertical shaft, cast iron cylinder, full pressure lube
with spin-on filter
Starting
System:
Electric-key switch operation with safety interlocks
on park brake, steering levers and blade drive.
Tires:
Front 11 x 4.00-5 smooth tread 16-21 PSI
(110-145 kPa)
Rear 18 x 7.50-8 4-ply turf tread 8-14 PSI
(55-97 kPa)
Capacities:
Fuel
Engine Oil
4.5 gallon (17 liters)
1.3 quarts (1.3 liters)
Dimensions:
Width
Height
Length
Weight
43" (109 cm) maximum track width
43" (109 cm) to top edge of seat
69" (175 cm) hitch tab to front
574 lbs. (260 kg)
Additional information may be provided elsewhere in this manual.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
15
SPECIFICATIONS
SpeedZTR™ 42 Model 968999546
Chassis:
1½" x 2" rectangle tubular side frame
Body:
Body parts are made of steel
Mower Deck:
42" (91cm) 13 gauge stamped 2 blade deck
Blade Drive:
Electric clutch
Transmission:
Each rear wheel is independently driven by a
Hydro Gear EZT hydrostatic drive with cooling
fan.
Engine:
16.5 HP Briggs & Stratton Intek, 4-cycle, single
cylinder, overhead valve, air-cooled, gasoline,
vertical shaft, cast iron cylinder, full pressure lube
with spin-on filter
Starting
System:
Electric-key switch operation with safety interlocks
on park brake, steering levers and blade drive.
Tires:
Front 11 x 4.00-5 smooth tread
16-21 PSI
(110-145 kPa)
Rear 18 x 8.50-8 4-ply turf tread
8-14 PSI
(55-97 kPa)
Capacities:
Fuel
Engine Oil
4.5 gallon (17 liters)
1.3 quarts (1.3 liters)
Dimensions:
Width
Height
Length
Weight
43" (109 cm) maximum track width
43" (109 cm) to top edge of seat
69" (175 cm) hitch tab to front
537 lbs. (244 kg)
Additional information may be provided elsewhere in this manual.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
16
SPECIFICATIONS
SpeedZTR™ 44 Model 968999547
Chassis:
1½" x 2" rectangle tubular side frame
Body:
Body parts are made of steel
Mower Deck:
44" (112cm) 11 gauge fabricated construction with
reinforced ribs.
Blade Drive:
Electric clutch
Transmission:
Each rear wheel is independently driven by a
Hydro Gear EZT self contained hydrostatic drive
Engine:
20 HP Briggs & Stratton, twin cylinder, overhead
valve, air-cooled, gasoline, vertical shaft, full
pressure lube with air filter, aluminum head and
block withcast iron cylinder liners
Starting
System:
Electric-key switch operation with safety interlocks
on park brake, steering levers and blade drive.
Tires:
Front 11 x 4.00-5 smooth tread16-21 PSI
(110-145 kPa)
Rear 18 x 9.50-8 4-ply turf tread 8-14 PSI
(55-97 kPa)
Capacities:
Fuel
Engine Oil
4.5 gallon (17 liters)
1.3 quarts (1.3 liters)
Dimensions:
Width
Height
Length
Weight
43" (109 cm) maximum track width
43" (109 cm) to top edge of seat
69" (175 cm) hitch tab to front
570 lbs. (259 kg)
Additional information may be provided elsewhere in this manual.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
17
SPECIFICATIONS
SpeedZTR™ 44 Model 968999538
Chassis:
1½" x 2" rectangle tubular side frame
Body:
Body parts are made of steel
Mower Deck:
44" (112cm) 11 gauge fabricated construction with
reinforced ribs.
Blade Drive:
Electric clutch
Transmission:
Each rear wheel is independently driven by a
Hydro Gear EZT self contained hydrostatic drive
Engine:
20 HP Kohler, single cylinder, overhead valve, aircooled, gasoline, vertical shaft, full pressure lube
with air filter, aluminum head and block withcast
iron cylinder liners
Starting
System:
Electric-key switch operation with safety interlocks
on park brake, steering levers and blade drive.
Tires:
Front 11 x 4.00-5 smooth tread16-21 PSI
(110-145 kPa)
Rear 18 x 9.50-8 4-ply turf tread 8-14 PSI
(55-97 kPa)
Capacities:
Fuel
Engine Oil
4.5 gallon (17 liters)
1.3 quarts (1.3 liters)
Dimensions:
Width
Height
Length
Weight
43" (109 cm) maximum track width
43" (109 cm) to top edge of seat
69" (175 cm) hitch tab to front
570 lbs. (259 kg)
Additional information may be provided elsewhere in this manual.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
18
CONTROLS
CONTROL LEVERS
For access to the seat, move control levers to neutral
position and swing them outward.
—Fig. 1—
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.
19
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
operator’s left.
•To engage brake, pull lever up (to the rear).
•To release brake, move lever forward (down).
—Fig. 2—
NOTE: Always set park brake before dismounting.
Release park brake before moving mower.
TRANSMISSION DRIVE SYSTEM
Allows the mower to turn on its own axis “ZERO TURNING
RADIUS”. Each lever controls one side of the mower.
NOTE: The pressure required to operate the mower is very light.
20
CONTROLS
BLADE DRIVE
•
•
•
Located on the operator’s right.
To engage the mower blade, pull the knob to the ON
position.
To disengage mower blade, push the knob to OFF
position.
THROTTLE CONTROL LEVER
•
•
•
Choke
Position
BLADE
DRIVE
Maximum
Throttle
Setting
STOP
15
PU
Located on control panel to
operator’s right.
Throttle control for engine
speed.
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.
SH
TO R ESE
CHOKE CONTROL
•
T
—Fig. 3—
Choke for engine starting. On the 36"
and 42" models, the choke is
combined with the throttle. See Fig. 3.
The 44" has a separate choke cable.
See Fig 4.
CHOKE
BLADE
DRIVE
CIRCUIT BREAKER
•
•
Protection of the electrical system is
by (1) 15 amp circuit breaker
If circuit breaker trips, push button
(lower left side of control panel ) to
reset.
If this condition repeats, consult dealer
for inspection and repair
21
STOP
15
PU
•
THROTTL
SH
TO R ESE
T
—Fig. 4—
CONTROLS
MOWER DECK CUT HEIGHT LIFT LEVER
•
Use right foot to operate deck foot pedal at right front foot
area.
•
To raise mower deck, push forward with right foot on top
portion of foot pedal. When desired deck height is
reached, push with right foot on lower portion of foot pedal
until bottom of the pedal engages in deck positioning
notch.
•
To lower deck, push forward with right foot on top portion of
foot pedal until bottom edge of pedal disengages deck
positioning notch. Lower deck to desired height and push
bottom portion of foot pedal until bottom edge engages
notch.
•
Never attempt to operate deck lift mechanism in any
manner other than foot method described above.
•
Always use highest position for transport.
22
OPERATION INSTRUCTIONS
The safe and successful operation of the SpeedZTR 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 who does not have complete
knowledge of all controls and their functions to operate the
mower.
NEVER dismount mower without applying park brake or
stopping engine.
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. Mower blade drive is off.
7. Steering levers are in outward position.
8. Know how to stop engine. (Turn key to OFF position).
23
OPERATION INSTRUCTIONS
!
WARNING
Failure to observe the following instructions
could result in serious injury or death.
STARTING INSTRUCTIONS
1. Park brake must be on, control levers in outward position
and blade drive disengaged.
2. Position throttle to choke position if engine is cold. Full
throttle if warm.
3. Insert ignition key and turn to START position. When
engine starts, release ignition key. Key will return to RUN
position.
4. Move throttle to maximum speed position.
5. Release park brake.
6. Swing levers inward.
7. Operate mower per “CONTROL” instructions on
Page 19.
!
CAUTION
Do not operate the engine in an enclosed
area due to the harmful exhaust gas
produced.
NOTE: 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.
24
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)
Always turn off engine before
engaging or disengaging the hydro
release (free wheel) lever. Never
attempt to move the lever with
the engine running.
Lift the seat to access
release levers. Push the
hydro release levers
toward the rear of the
machine and inward until
notches lock in place on
frame. (See Fig. 4)
Release park brake.
To engage the
transmissions, move the
release levers outward so
they return to normal
position.
—Fig. 4—
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.
25
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. Swing control levers to outward position.
2. Disengage blade drive.
3. Put park brake in OFF position.
4. Turn ignition switch to START.
ENGINE SHOULD NOT TURN OVER OR
ATTEMPT TO START.
CONTROL LEVER SWITCH TEST
1. Disengage blade drive.
2. Put park brake in ON position.
3. Swing control levers inward.
4. 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.
26
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. Put park brake in ON position.
2. Swing control levers to outward position.
3. Engage blade drive switch.
4. 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 engine.
2. Leave control levers in outward position and put park
brake in OFF position.
3. Rise slightly off seat. Engine should stop!
4. Restart engine.
5. Leave control levers in outward position and put park
brake in ON position.
6. Make sure area is clear of bystanders. Engage blade
drive and rise slightly off the 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.
27
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.
28
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.
It may be necessary to cut your 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!
29
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.
30
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/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.
!
•
•
•
•
•
•
WARNING
Failure to observe the following instructions
could result in personal injury.
Watch for low hanging branches or other obstacles which
might hit the catcher top while turning or backing the
mower.
Use care when backing to 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.
31
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 on Page 44-45.
!
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,
should you place 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.
32
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
Bermudagrass
Bluegrass
Buffalograss
Ryegrass
Tall Fescue
Zoysiagrass
Best Cut Heights
1 - 2" (25-51 mm)
2 - 3" (51-76 mm)
1½ -3" (38-76 mm)
2 - 3" (51-76 mm)
3-3½" (76-89 mm)
1 - 3" (25-76 mm)
33
CARE AND MAINTENANCE
!
WARNING
Failure to observe the following instructions
could result in serious injury or death.
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
•Check deck drive belt ..................................... after 20 hours break-in
•Check crankcase oil level .......................................... before each use
•Clean grass & debris from muffler & manifold area .... before each use
•Check air intake screen ................................................ after each use
•Clean grass under deck ............................................... after each use
•Check tire pressure ...................................................... every 10 hours
•Inspect blades for sharpness ....................................... every 10 hours
•Clean air filter element ................................................. every 25 hours
•Grease all zerks .......................................................... every 50 hours
•Check all belts .............................................................. every 50 hours
•Change engine crankcase oil. .................... after 5 hours break-in and
..................................... every 50 hours
•Change engine oil filter ................................................ every 50 hours
•Replace air filter element ........................ annually or every 100 hours
34
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. Be sure blade is
centered on pilot before tightening.
See chart.
Deck Size:
36" and 44"
50-60 ft. lbs. (68-81 Nm)
—Fig.5—
Tighten to:
36",44"
50-60 ft. lbs. (68-81 Nm)
42"
35 ft. lbs. (48 Nm)
Blades should be discarded
when worn excessively.
42"
35 ft. lbs. (48 Nm)
—Fig.6—
New blade
—Fig. 7—
When notch starts,
discard blade
35
DANGEROUS!
Do not use blade
in this condition!
CARE AND MAINTENANCE
ENGINE
For complete maintenance and operating information of the
engine, please refer to the maintenance instructions
furnished by the engine manufacturer included in your Zero
Turn Radius mower information packet.
!
CAUTION
Battery contains sulfuric acid electrolyte
that is poisonous and corrosive.
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.
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. Contact your dealer
for more information.
36
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 36"
Rear tires 42"
Rear tires 44"
11 x 4.00 - 5
18 x 7.50 - 8
18 x 8.50 - 8
18 x 9.50 - 8
16-21 PSI
8-14 PSI
8-14 PSI
8-14 PSI
(110-145 kPa)
(55-97 kPa)
(55-97 kPa)
(55-97 kPa)
Lug nuts or lug bolts should be checked regularly for tightness.
LUBRICATION
CHASSIS:
LOCATIONS:
SERVICE INTERVALS:
RECOMMENDED
GREASE:
(9) grease zerks
(2) front wheel axles
(2) front wheel casters
(2) deck lift shaft
(2) control levers
(1) mower deck hub
Every 50 hours of operation or
once per season.
Name brand wheel bearing
or multipurpose grease
(3 pumps each)
Caster/Axle
Lift Shaft
—Fig. 8—
37
Control Levers
CARE AND MAINTENANCE
!
CAUTION
HOT oil may cause burns. Allow engine to
cool before draining oil.
CHANGING THE ENGINE OIL
1. The “Dapco” oil drain valve is located on the left side of
the engine crankcase.
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. (See
Fig. 9) Open to full open (approximately 7 turns).
Hex Head Valve Stem
—Fig. 9—
4. After engine is drained, tighten hex stem.
5. Change oil filter.
6. 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. Make sure the hex stem on drain valve has been
tightened.
3. Refill engine with type and quantity of oil recommended
by the engine manufacturer in engine literature.
NOTE: Engine oil changes on the SpeedZTR™ will require
replacement of the oil filter. These filters may be available
from your authorized Dixon dealer.
38
CARE AND MAINTENANCE
BELTS
Check belts every 50 hours. Replace any belts showing
signs of wear or cracking.
BELT TENSION
Transmission Drive Belt - P/N 539 120772
No adjustment necessary.
Engine to Mower Deck Belt
36" P/N 539 117811
42" P/N 539 122734
44" P/N 539 118156
To adjust the tension of
the mower deck drive
belt, turn adjuster nut on
threaded eyebolt.
Turning nut to the left
will loosen the belt, see
Fig 10. Idler arm, spring
and eyebolt location/
appearance will vary on
some models.
—Fig. 10—
NOTE: Engaging the
blade clutch may produce a sharp, high pitched chirp or
squeal as the belt tension loading is absorbed by the
idler system. This is normal and not a sign of failure.
Belt deflection or movement should be approximately ¼"
when measured at mid-point between pulleys.
Periodically inspect both belt and idler systems.
39
CARE AND MAINTENANCE
NEUTRAL ADJUSTMENT
Drive machine until Hydrostatic Transmissions have warmed
up. With engine running and the park brake off, swing the
control levers outward. If machine starts to creep, follow the
instructions below.
1. Stop the engine, engage park brake and raise rear of
frame with jack or blocks so that rear tires do not contact
the ground.
2. Swing control levers outward, start the engine and release
the park brake.
3. Raise the seat to access hydro control linkage. If right
wheel creeps, adjust right side linkage and vice-versa.
Use procedure below, see Fig. 11.
a. Loosen jam nut on end of the coupler
P/N 539 116689.
b. If right wheel is creeping forward, turn coupler
counter-clockwise until neutral is achieved (clockwise for left side). If right wheel is creeping backward, turn coupler clockwise until neutral is achieved
(counter-clockwise for left
side).
c. Tighten jam nut against
coupler.
4. Stop engine and remove
rear of machine from jack
or blocks.
—Fig. 11—
40
CARE AND MAINTENANCE
MOWER DECK LEVELING PROCEDURE
1. Place mower on a smooth, level surface and rotate
casters in the direction of forward travel. Tires should be
inflated as follows.
Front 16 - 21 PSI (110-145 kPa)
Rear
8 - 14 PSI (55-97 kPa)
2. Put the mower deck in the mid-range cut height position.
3. Turn blade so the two outer blade tips each point
outward.
4. Turn front adjuster nut(s) to level deck side to side.
5. Turn all bladed so tips point to the front and rear.
6. Turn rear adjuster nut(s) until blade is level to
¼" (6mm) higher in the rear, see Fig. 12.
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.
—Fig. 12—
41
CARE AND MAINTENANCE
DECK REMOVAL
1. Place cut height pedal in lowest cut position.
2. Remove deck drive belt from engine pulley.
3. Release spring from trailing rod (2 places). Remove
hairpin cotter from the other end of trailing rods
(2 places) and detach rods from deck.
4. Remove hairpin cotter from top of front L-Rods
(2 places) and detach L-Rods from lift arms.
5. Remove hairpin cotter from top of rear L-Rods
(2 places) and detach L-Rods from lift arms.
6. Carefully raise and support front of chassis. Slide mower
deck to either side for removal. (Reverse procedure to
reinstall deck assembly.)
—Fig. 13—
42
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 (page 15).
PARTS/SERVICE
See your authorized Dixon dealer for replacement parts,
warranty or service.
43
STANDARD SERVICE PARTS LIST
BLADES AND BELTS
36" Deck
Blade
* Hi-Lift Fusion
Standard Lift Fusion
Standard Lift
Hi-Lift Gator Fusion
Gator
Transmission Belt
P/N 539 118672
P/N 539 115536
P/N 539 115242
P/N 539 118673
P/N 539 125846
P/N 539 120772
Deck Belt
P/N 539 117811
Deck Belt
P/N 539 122734
Deck Belt
P/N 539 118156
42" Deck
Blade
* Hi Lift Fusion
Hi-Lift Transmission Belt
P/N 539 119843
P/N 539 119851
P/N 539 120772
44" Deck
Blade
* Hi Lift Fusion Super Hi-Lift Fusion Standard Lift Fusion Gator Fusion Hi-Lift Standard Lift Transmission Belt
P/N 539 119836
P/N 539 119798
P/N 539 119860
P/N 539 119862
P/N 539 119858
P/N 539 119859
P/N 539 120772
*Factory installed
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.
44
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
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
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 23)
7. MOWER LOSES POWER OR TRANSMISSION OVERHEATS
Engine air filter - - - - - - - - - - - - - - - - - - - - - - - - - - - clean or replace
Transmission damage - - - - - - - - - - - - - - - - - - - - - - consult dealer
45
TROUBLESHOOTING
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
46
OWNER’S INFORMATION
Date of Purchase ________________________________
Mower Model Number _____________________________
Mower Serial Number _____________________________
Purchased From ________________________________
Name
________________________________
Address
________________________________
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.
SpeedZTR 36/42/44
Part No. 539 121042R1
10/04/06
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