ZTR®
OPERATOR’S MANUAL
2003
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INDEX
Page
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . . . . . . . .14
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-17
Operation Instructions. . . . . . . . . . . . . . . . . . . 18-27
Care & Maintenance. . . . . . . . . . . . . . . . . . . . . .28-38
Standard Service Parts List. . . . . . . . . . . . . . . . . . . .39
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 40-41
ZTR Classic
Part No. 13639-0702
3
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SAFETY
RIDING LAWN MOWERS,
IF IMPROPERLY OPERATED,
CAN CAUSE SERIOUS INJURY OR DEATH.
The most common causes of injury to the operator or bystander...
BLADE CONTACT
TIP OVER
RUN OVER
BACK OVER
...read and understand this manual to prevent injuries.
4
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SAFETY
Safety Alert Symbol
When you see this symbol,
BE ALERT to the potential for injury.
Follow 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
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SAFETY
Failure to observe the following safety
instructions could result in serious injury or death.
GENERAL OPERATION:
•Read, understand, and follow all instructions in the
manual and on the mower before starting.
•Only allow responsible adults, who are familiar with
the instructions, to operate the mower.
•Clear the area of objects such as rocks, toys, wire,
etc., which could be picked up & thrown by the blade.
•Be sure the area is clear of other people before
mowing. Stop mower if anyone enters the area.
•NEVER carry passengers.
•Do not mow in reverse unless absolutely necessary.
Always look down & behind before & while backing.
•Be aware of the mower discharge direction and do
not point it at anyone.
•Do not operate the mower without either the entire
grass catcher or the deflector in place.
•Slow down before turning.
•Never leave a running mower unattended. Always
turn off blades, set parking brake, stop engine and
remove key before dismounting.
6
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SAFETY
GENERAL OPERATION (continued):
•Turn off blades when not mowing.
•Stop engine before removing grass catcher or
unclogging chute.
•Mow only in daylight or good artificial light.
•Do not operate the mower while under the
influence of alcohol or drugs.
•Watch for traffic when operating near or
crossing roadways.
•Use extra care when loading or unloading the
mower into a trailer or truck. Do not ride the
mower when loading and unloading.
•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.
•Follow the manufacturer’s recommendation for
wheel weights and counterweights.
•Maintain or replace safety & instruction labels
as needed.
The engine exhaust from this product contains chemicals known to the
State of California to cause cancer, birth defects or other reproductive
harm.
WARNING:
7
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SAFETY
SLOPE OPERATION:
Slopes are a major factor related to loss-of-control and tip-over
accidents, which can result in severe injury or death.
All slopes require extra caution.
If you cannot back up the slope or if you feel uneasy on it,
do not mow it!
DO
•Mow across the slope with your Dixon ZTR - never up or down.
•Remove obstacles such as rocks, tree limbs, etc.
•Watch for holes, ruts or bumps. Uneven terrain could overturn the
mower. Tall grass can hide obstacles.
•Use slow speed. Tires may lose traction on slopes even though the
brakes are functioning properly.
•Use extra care with grass catchers or other attachments. These can
change the stability of the mower.
•Keep all movement on the slopes slow and gradual. Do not make
sudden changes in speed or direction.
•Avoid starting or stopping on a slope. If tires lose traction, disengage
the blades and proceed slowly down the slope.
•If front wheels lift off the ground, pull the levers back to stabilize the
mower.
DO NOT
•Do not turn on slopes unless necessary, and then, turn slowly and
gradually downhill, if possible.
•Do not mow near drop-offs, ditches, or embankments. The mower
could suddenly turn over if a wheel is over the edge of a cliff or ditch,
or if an edge caves in.
•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 on steep slopes.
8
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SAFETY
CHILDREN:
Tragic accidents can occur if the operator is
not alert to the presence of children.
Children are attracted to lawn mowers
and the mowing activity.
NEVER assume children will stay
where they were last seen.
Be alert to avoid accidents.
•Keep children out of the mowing area and under the
watchful care of another responsible adult.
•Be alert and turn mower off if a child enters the
area.
•Before and during backing, look BEHIND and DOWN
for small children.
•Never carry children. 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.
9
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SAFETY
SERVICE:
•Use extra care in handling gasoline and other fuels.
They are flammable and vapors are explosive.
Use only an approved container.
Never remove fuel cap or add fuel with engine
running. Allow engine to cool before refueling.
Do not smoke while refueling.
Never refuel the mower indoors.
Never store the mower or fuel container inside
a building where there is an open flame.
If fuel is spilled on clothing, change clothing
immediately.
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, then 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.
10
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SAFETY
SERVICE (continued):
•Never run a mower inside a closed area. The
exhaust fumes are toxic.
•Keep nuts and bolts tight, especially blade
attachment bolts, and keep equipment in good
condition.
•Never tamper with safety devices. Check their
proper operation regularly.
•Keep mower free of grass, leaves, or other
debris buildup. Clean up oil or fuel spillage. Allow
mower to cool before storing.
•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, which could expose
moving parts or allow objects to be thrown.
Frequently check components and replace with
original equipment parts, when necessary.
•Mower blades are sharp and can cut. Wrap
the blade(s) or wear gloves, and use extra caution
when servicing them.
•Batteries contain sulfuric acid. To prevent burns
avoid contact with skin, eyes and clothing. To
prevent a fire or explosion keep sparks and open
flames away from battery.
•Before disconnecting the negative (-) ground cable,
make sure all switches are OFF.
11
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DIXON PROTECTION PLUS TWO YEAR LIMITED WARRANTY
TRANSAXLE MODELS
WARRANTY: Home Owner Application: Dixon Transaxle Models, used only at owner’s primary
place of residence are warranted for a period of two (2) years from date of purchase.
Commercial Application: defined as use other than, or in addition to, mowing at owner’s primary
place of residence. Dixon Transaxle Models, used in commercial application are warranted for
a period of (30) days from the date of purchase.
DIXON ZTR MOWERS ARE WARRANTED AGAINST DEFECTS IN MATERIALS AND
WORKMANSHIP AND PROVIDES FOR REPLACEMENT OR REPAIR OF PARTS INCLUDING LABOR
COSTS. THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS AND LIMITATIONS:
1.
Warranty applies only to original retail purchaser of new and unused mowers and
accessories.
2.
All Dixon warranty must be accomplished by authorized Dixon dealers and in
accordance with Dixon warranty policy and allowances. All warranty claims must be
approved by Dixon Industries, Inc.
3.
4.
Battery warranty: Limited to 90 days from date of purchase.
Accessories Warranty (Grass Catchers, Snow Blades, Covers, etc.): Limited to 90
days from date of purchase.
5.
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 Industries, Inc. VOIDS ALL WARRANTY.
The following items are not covered by this warranty policy:
(a) Pick up and delivery charges for transportation of mower to and from an
Authorized Dixon Dealer's place of business.
(b) Routine maintenance or adjustments (including transaxle adjustments)
(c) Belts/Blades/Chains/Sprockets
(d) Engines -- All engines used on Dixon ZTR mowers are warranted by each
individual engine manufacturer.
(e) Any costs or expense of providing substitute equipment while repair work is
being performed on a warranted mower.
7.
There is no other express warranty. Implied warranties, including those of merchant
ability and fitness for a particular purpose, are limited to the same duration of the
express warranty, and to the extent permitted by law any and all implied warranties
are excluded. Liabilities for consequential damages under any and all warranties are
excluded.
Copies: Pink/Customer
Yellow/Dealer
White/Return to Dixon Ind.
WARRANTY VALIDATION: At the time of sale, selling dealer must review each portion of this
warranty document, complete the information section below, secure customer's signature and
send copy to Dixon Industries, Inc.
Date of Purchase
Model
Deck Size
S/N
(Owner's Name)
(Street Address)
(City/State/Zip)
(Dealership Name & Dealer Number)
(Street Address)
(City/State/Zip)
(Owner's Signature)
(Dealer's Signature)
DIXON INDUSTRIES, INC.
A BLOUNT International Inc. Co.
PO BOX 1569
COFFEYVILLE KS 67337 0945
PHONE 620 251 2000
1-877-CUT-MORE
FAX 620 251 4117
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SPECIFICATIONS
ZTR Classic
CHASSIS:
BODY:
11 GA welded rectangular tubing
All body parts made of high density polyethylene. Dent
and corrosion resistant. Front body contains access
panel for battery service.
MOWER DECK:
13 GA stamped steel construction. Three blades
combine for a 42” cut width. Cut height approximately
1”- 4” via 7-position lift handle.
BLADE DRIVE:
Electric clutch.
TRANSMISSION:
Each rear wheel is independently driven by chain and
sprockets through a mechanical friction drive.
ENGINE:
14.5 HP Briggs & Stratton Intek, 4-Cycle, Single Cylinder,
Overhead Valve, Air-Cooled, Gasoline, Vertical Shaft with
Cast Iron Cylinder, AVS (Anti-Vibration System), Pressure
Lube & Filter.
STARTING SYSTEM:
TIRES:
Electric by key switch operation with safety interlock
blade drive.
Front 11 x 4.00-5 ribbed tread.
Rear
18 x 8.50-8 Turf Trac R/S
RECOMMENDED
TIRE PRESSURE:
Front 16-21 PSI
Rear
Fuel
8-14 PSI
CAPACITIES:
DIMENSIONS:
2.4 gallons total
Engine 1.5 quarts oil
Width 47” outside rear wheel measurement
Height 42” to top edge of seat
Length 72” hitch tab to front bumper
Weight 520 lbs.
Additional information provided in service instructions under the individual component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
13
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SEAT ADJUSTMENT INSTRUCTIONS
Model ZTR Classic
1.
2.
Raise and push seat assembly forward.
Loosen seat adjustment knobs and slide
seat forward or backward to desired
position.
3.
4.
Re-tighten nuts. DO NOT operate mower
without seat adjustments properly
tightened.
Push seat assembly back to closed
position.
14
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CONTROLS
The Dixon ZTR has a unique transaxle that requires only two drive levers to
control braking, turning, speed and direction.
On initial operation, set throttle speed on slow. Operate with mower
blade in “OFF” position.
To avoid “over-controlling” the mower, use a light touch on the drive
levers.
Slight movements using fingertip control is all that is necessary.
PARKING BRAKE:
The parking brake is designed to hold the mower
from moving and is not intended for use in stopping the
mower while it is in motion.
Engage parking brake
before starting engine.
CAUTION
TO SET PARKING BRAKE:
The hand operated parking brake is located on the right
end of the mower.
To engage brake, pull lever up (to the rear).
To release brake, move lever forward (down).
NOTE: Always set parking brake before dismounting.
Release parking 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.
15
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CONTROLS
CONTROL LEVERS
TO GO FORWARD:
•From neutral position, gently push both control levers forward.
•To increase speed, move levers further forward.
TO GO BACKWARD:
•From neutral position, gently pull both 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.
LEFT TURN OPPOSITE
Note: The pressure required to operate the mower is very light.
16
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CONTROLS
BLADE DRIVE:
•Located on the control panel, on the
operator’s right.
•To engage the mower blades, pull up on
the switch.
•To disengage mower blade, push down.
CIRCUIT BREAKER:
•Protection of the electrical system is by
(1) 15 amp circuit breaker.
•If circuit breaker trips, push button to
reset.
•If this condition repeats, consult dealer
for inspection and repair.
THROTTLE CONTROL LEVER:
•Located on control panel to operator’s right.
•Throttle control for engine speed.
•Choke for engine starting.
•Throttle control should be set to MAXIMUM
or wide open setting to ensure adequate
cooling of the engine and to maintain mower
deck blade speed while mowing.
MOWER DECK LIFT LEVER:
•Located to the right of the control levers.
•Controls the cutting height.
•Eight positions of adjustment.
•Move lever left and forward to lower.
•Move lever left and back to raise.
NOTE: Always use high for transport.
17
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OPERATION INSTRUCTIONS
The safe and successful operation of the ZTR Classic
mower will depend upon the operator having the cor-
rect knowledge of all the controls used on the mower
and making good judgements about the terrain to be
mowed.
NEVER allow anyone to operate the mower without
complete knowledge of all controls and their functions.
During initial operation, “learning to drive”, set throttle at
slow speed.
Sound judgement by the operator will prevent accidents.
TOWING:
Towing a trailer or other attachment that is too heavy
could damage the drive or cause the mower to
become unstable. Limit loads to 250 pounds or less
with this mower.
18
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OPERATION INSTRUCTIONS
BEFORE OPERATING MOWER:
1.
Read and observe all safety instructions on
your mower and in the manual.
2.
Read engine manufacturer’s operating and
maintenance instructions.
3.
4.
5.
6.
7.
Check engine oil.
Check fuel cap to be sure it is in place.
Be sure parking brake is on.
Mower blade drive is off.
Know how to stop engine. (Turn key to off
position).
19
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OPERATION INSTRUCTIONS
TESTING OF SAFETY INTERLOCK SYSTEMS:
Do not operate mower if safety switches are not operating properly.
BLADE DRIVE SWITCH TEST:
a) Engage blade drive switch.
b) Turn ignition switch to START.
ENGINE SHOULD NOT TURN OVER
OR ATTEMPT TO START!
SEAT SWITCH TEST:
a) In a SAFE AREA away from bystanders,
start the engine.
b) Engage blade drive switch.
c) Raise slightly off seat.
ENGINE SHOULD STOP!
If any safety check fails: Do not operate the mower
until the system has been checked and repaired
by an authorized Dixon ZTR dealer!
20
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OPERATION INSTRUCTIONS
STARTING INSTRUCTIONS:
1.
2.
Parking brake must be on, and blade drive disengaged.
Move throttle control to “choke” position if engine is cold,
full throttle if warm.
3.
Insert ignition key and turn to “start” position. When
engine starts, release ignition key. Key will return to
“run” position.
4.
5.
6.
Move throttle from “choke” to desired speed position.
Release parking brake.
Operate the mower per the “CONTROL” instructions on
Page 16.
CAUTION
Do not operate the engine in an enclosed area
due to the harmful exhaust gas produced.
Note: When mowing, “blade(s) engaged”, throttle control must be set
to the MAXIMUM or wide open setting to insure adequate cooling
of the engine and to maintain mower deck blade speed.
21
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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
Be sure that the deflector is properly
installed on the discharge chute.
1,
2.
Set engine speed control to the wide open or full
setting.
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.
5.
Maintain Sharp Blade(s) Throughout The Cutting
Season.
22
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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 1/3 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 an adequate
moisture conditions and normal thatch build-up 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”
2 - 3”
11/2 -3”
2 - 3”
3-31/2
1 - 3”
”
23
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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 of the recycled or mulched clippings.
In order to achieve the best results, please read and follow the
mulching tips listed below:
1.
Set the engine speed control to the wide open
or full setting.
2.
Place the mower deck cut height selector in
either the top or second notch. Never cut
more than 3/4” to 1” off the grass at any one
time. Attempting to cut more grass will result
in the deck plugging and cause the engine to
stall.
3.
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.
4.
5.
Do Not Attempt To Cut Grass When It Is Wet.
Mulching performance will be very poor under
wet grass conditions.
Maintain Sharp Blade(s) Throughout The Cutting
Season. This is very important. Optimal
mulching performance cannot be obtained with
a dull or nicked-up blade.
24
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OPERATION INSTRUCTIONS
MOWING WITH A MULCHING ATTACHMENT
(continued):
6.
7.
Keep the Underside Of The Mower Deck Clean.
Remove all grass and dirt build-up from the
underside of the pan, the baffles and deflectors
after each use.
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 satis-
factory, try one or more of the following tips:
1.
2.
3.
4.
5.
6.
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!
25
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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.
2.
Set engine speed control to the wide open or
full setting and engage mower before entering
area to be cut.
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.
3.
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.
4.
5.
Keep The Underside Of The Mower Deck Clean.
Frequent removal of dried grass and dirt will
greatly assist in bagging of the clippings.
Use only the correct blade(s). Some grass
catching attachments require a “high-lift” blade.
See your dealer for advice on the type of blade(s)
needed for your mower.
6.
Maintain Sharp Blade(s) Throughout The
Cutting Season.
26
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OPERATION INSTRUCTIONS
MOWING WITH A GRASS CATCHER ATTACHMENT
(continued):
7.
8.
Operate the mower at a slower ground speed
than when mowing without a grass catching
attachment.
Some mowing applications/use of grass
catchers may require that an optional weight
box 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.
CAUTION
•
•
•
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.
Disengage blade and stop engine prior to
clearing grass from either the discharge chute
or grass catcher components.
•
•
Keep all attachment bolts tight.
Do Not operate the mower with the grass
catching attachment partially removed.
•
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.
27
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CARE AND MAINTENANCE
CAUTION
Before performing any maintenance, turn off engine,
allow to cool & remove key.
Use extreme care when working on machinery.
Do not wear watch or jewelry. Do not wear loose fitting clothes,
and observe all common safety practices with tools.
MAINTENANCE SCHEDULE
•Check deck serpentine 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............................(5 hours break-in) every 50 hours
•Change engine oil filter..............................................................every 50 hours
•Replace air filter element..........................................annually or every 100 hours
28
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CARE AND MAINTENANCE
ENGINE:
For complete maintenance and operating information of the engine,
please refer to the maintenance instructions furnished by the engine
manufacturer and included in your Zero Turn Radius mower informa-
tion packet.
BATTERY:
Battery contains sulfuric acid electrolyte which is
poisonous and corrosive.
CAUTION
•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.
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 11 x 4.00-5 16-21 lbs. PSI
Rear Tires
18 x 8.50-8 8-14 lbs. PSI
Lug nuts or lug bolts should be checked regularly for tightness.
29
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CARE AND MAINTENANCE
CUTTER BLADE MAINTENANCE:
CAUTION
Stop engine and remove ignition key for safety.
Wear heavy, thick gloves when holding onto
cutter blade. Avoid the sharp edge of the blade.
Check sharpness of mower blades after every 10 hours of operation.
Observe proper blade position prior to removal.
1.
2.
3.
4.
Safely raise front of mower.
Hold or block blade from turning.
Loosen blade nut and remove blade.
When replacing blade, tighten
blade nut securely. Refer to diagram.
Be sure blade is centered on pilot
before tightening nut to 60 ft. lbs.
Blades should be discarded when worn excessively.
DANGEROUS!
DO NOT USE
BLADE IN
THIS CONDITION!
New Blade
When notch
starts, discard blade
30
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CARE AND MAINTENANCE
BELTS:
Check belts every 50 hours. Replace any belts found to
be in poor condition.
BELT TENSION:
Transaxle Drive Belt:
P/N 1684
P/N 6111
No adjustment required.
Engine to Mower Deck Belt:
No adjustment required. Correct belt tension is
maintained through a fixed engine location and a
spring loaded idler system. A pulsing movement of
the belt idler will be observed both during engagement
of the electric blade clutch and actual operation of the
mower deck.
Note: Engagement of the electric blade clutch switch
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.
Mower Deck Serpentine Belt:
P/N 6109
Refer to illustration for adjustment procedure.
Idler Weldment
Idler Shock Mount
“L” Rod
Hex Nut
3
4
Tighten or
Loosen Hex
Nut to
achieve this
dimension
31
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CARE AND MAINTENANCE
MOWER DECK LEVELING PRCEDURE:
1.
Place mower on a smooth, level surface and check
tire pressures to insure correct stance. Tires
should be inflated as follows:
Front: 16-21 lbs
Rear:
8-14 lbs
2.
3.
Turn each outer blade tip to align with the deck in
a side to side manner.
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 measure-
ment is the same. If adjustment is required, turn
nut on one or both of the rear L-rods until both
measurements are equal.
4.
5.
Turn each outer blade tip to align with the deck in
a front to rear manner.
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 3/8”
higher than the front of blade tips. If adjustment is
necessary, turn nut on front L-rod.
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.
32
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CARE AND MAINTENANCE
DECK REMOVAL:
1.
2.
Place cut height lever in lowest cut position.
Pull belt idler back to allow belt to be removed
from idler pulley and electric clutch pulley.
3.
4.
5.
Remove hair pin cotter and washer from one
end of deck support cross shaft. Slide shaft
from chassis and mower deck.
Remove hair pin cotter and washer from each
deck L-rod. Remove L-rods from lift arms. At this
point, deck will drop down.
Carefully raise and support front of chassis.
Slide mower deck to either side for removal.
(Reverse procedure to reinstall deck assembly.)
Note: When deck is reinstalled on frame, check
that belt is correctly routed in the groves
of all pulleys and that belt idler is applying
tension to the back side of the belt.
33
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CARE AND MAINTENANCE
HOT oil may cause burns. Allow
engine to cool before draining oil.
CAUTION
CHANGING THE ENGINE OIL:
1.
2.
3.
The “Dapco” oil drain valve is located on the left
side of the engine crankcase.
Place a suitable container under the drain valve
hose.
To drain, turn hex head valve stem counter--
clockwise with 10mm wrench or socket. Open
to full open (approximately 7 turns).
4.
5.
6.
After engine is drained, tighten hex stem.
Change the oil filter.
Fill with oil (see steps below).
NOTE: Refer to engine manufacturer’s recommendations
for frequency of oil changes.
Hex Head Valve Stem
OIL FILL:
1.
2.
Clean any spilled oil from engine and chassis.
Refill engine with type, and quantity of oil
recommended by the engine manufacturer in
engine literature.
34
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CARE AND MAINTENANCE
DRIVE SYSTEM ADJUSTMENTS:
Due to both the complex nature of the transmission
and the number of special tools required for service,
adjustments should be entrusted to your dealer.
There are a number of simple owner service items
which greatly influence the performance of the drive
system.
1. Front and rear tires must be inflated to proper
specifications.
2. Rear drive chain tension.
3, Tightness of all controls and linkages pertaining
to the drive levers.
4. Lubrication of both primary and final drive chains.
The use of a high quality chain lubricant is highly
recommended.
35
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CARE AND MAINTENANCE
REAR CHAIN ADJUSTMENT:
To adjust the rear drive chains on the ZTR Classic,
tighten the nut on top of the spring on each side of
the mower chassis. Tighten until the chains have
approximately 1/4” movement up and down when
measured at a mid point. Refer to illustration.
NOTE: Adjust rear drive chains after first 10 hours of
operation and every 40 hours thereafter.
36
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CARE AND MAINTENANCE
LUBRICATION:
CHASSIS:
(5) grease zerks used
LOCATIONS:
(1) each front wheel caster
(1) each mower deck hub
SERVICE INTERVALS:
Every 50 hours of operation
RECOMMENDED GREASE: Name brand wheel bearing or
multi-purpose grease. Once
per season or 50 hours of
operation (3 pumps each)
Note: Lubrication of the mower deck hubs will help dispel moisture
within the hub casting. Bearings are of a sealed variety.
PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS.
PROTECT YOUR ENVIRONMENT.
37
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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, causing corrosion.
SERIAL NUMBERS:
The serial number is located on the frame at the
rear of the engine.
WARRANTY:
See Warranty Registration (sample on page 12).
PARTS/SERVICE:
See your Dixon dealer for replacement parts,
warranty or service.
38
PLEASE HELP PROTECT THE ENVIRONMENT BY AVOIDING ALL
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CHEMCIALS WHICH MAY DAMAGE OR CAUSE HARM TO
STANDARD SERVICE PARTS LIST
Blades:
Belts:
P/N 8688 (Standard/Hi-Lift)
P/N 6236 (Lo-Lift)
Engine to Mower Deck - P/N 6111
Engine to Transmission - P/N 1684
Serpentine Blade Drive - P/N 1684
BRIGGS & STRATTON AIR AND OIL FILTER PART NUMBERS:
Refer to engine manufacturers manual for correct
service intervals for engine oil changes and air filter
maintenance.
Protect your engine investment, use only original
equipment filters.
39
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TROUBLESHOOTING
1.
ENGINE WON’T TURN OVER
Mower blades engaged- - - - - - - - - - - - - - - - - - - - - - -disengage blades
Circuit Breaker Trips- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -reset breaker
Dead battery- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - charge or replace
Solenoid- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Ignition switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Starter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
2.
3.
ENGINE WILL TURN OVER BUT WON’T START
No fuel- - - - - - - - - - - - - - - refuel and/or clean or replace fuel filters
HARD TO START ENGINE
Fuel line clogged- - - - - - - - - - - - - clean fuel line and check fuel filter
Faulty fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
4.
5.
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- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - check vent
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
40
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TROUBLESHOOTING
6.
7.
8.
ENGINE RUNS BUT MOWER WON’T MOVE FORWARD
Drive belt broken or slipping- - - - - - - - - - - - - - - - - - - - replace drive belt
Bad transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
MOWER LOSES POWER OR TRANSMISSION OVERHEATS
Engine air filter-- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -clean or replace
Transmission damage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
ENGINE STALLS WHEN BLADES ARE ENGAGED
Operator not on seat- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -sit on seat
Faulty interlock system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
Bad blade spindle bearing - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Deck drive belt not properly routed- - - - - - - - - - - - - - - - - - - - - - - reroute
Blades blocked by foreign material - - - - - - - - - - - - - -clean under deck
9.
DRIVE SYSTEM
Low on power- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - check belt tension
Mower pulls to side - - - -check tire inflation/adjust control linkage
Mower creeps in neutral- - - - - - - - - - - - - - - - - - - -adjust control linkage
10.
CUT QUALITY
Skips in spots- - - - - - - - - - - - check for loose belt/slow ground speed
Cut uneven left to right - - - - - - - - -check tire inflation/level the deck
Poor dispersal of grass- - - - - - - - - - -clean deck/check for loose belt
Ends of grass blades are ragged- - - - - - - - - - - - - - - - - -sharpen blades
41
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NOTES
42
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OWNER
INFORMATION
DIXON INDUSTRIES, INC.
a BLOUNT International Inc. Co.
P.O. Box 1569
Coffeyville, Ks 67337-0945
620-251-2000
FAX 620-251-4117
Date Purchased _________________________________
Mower Model Number ____________________________
Mower Serial Number ____________________________
Purchased From ________________________________
Name
________________________________
Address
________________________________
DATE OIL CHANGED:
DATE ENGINE TUNED:
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
43
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ZTR®Mowers
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects or other reproductive harm.
WARNING:
Dixon® and ZTR® are registered trademarks
of Dixon Industries, Inc.
DIXON INDUSTRIES, INC.
a BLOUNT International Inc. Co.
P.O. Box 1569
Coffeyville, Ks 67337-0945
620-251-2000
ZTR Classic
Part No. 13639-0702
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