Dixon Black Bear User Manual

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BLACK BEARZTR®

Safety Instructions & Operator’s Manual

Model Year 2005

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® Black Bear™ 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®.

2

TABLE OF CONTENTS

 

Page

SAFETY&WARNING....................................

4-15

WARRANTY........................................................

16

SPECIFICATIONS.............................................

17

SEATADJUSTMENT........................................

18

CONTROLS..................................................

19-22

OPERATIONINSTRUCTIONS....................

23-33

CARE& MAINTENANCE...........................

34-47

TROUBLESHOOTING.................................

48-49

STANDARD SERVICE PARTS LIST..............

50

BLACK BEAR™

Part Number 11249-0605

3

SAFETY

RIDING LAWN MOWERS,

IF IMPROPERLY OPERATED

CAN CAUSE SERIOUS INJURY OR DEATH

Pictured beloware the most common causes of injury to the operatoror bystander. Please read and understand this manual topreventinjuries.

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 imminentlyhazardous

situation which, if not avoided, will result in death or serious injury.

WARNING

(highlightedin 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

WARNING

Failure to observe the following safety instructions could result in serious injury or death.

GENERAL OPERATION:

Read, understand, andfollowall instructions inthis 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 and thrown by the blade.

Be sure the area is clear of other people before mowing. Stop mower if anyone enters the area.

Beawareofthemowerdischargedirectionanddonotpoint it atanyone. Mowerbladescan throwrocksorother debris.

Do not operate the mower without either the entire grass catcher or the deflector in place. This will decrease the possibility of injuryfrom objects beingthrown bythe mower blades.

Never carry passengers. They may fall off and become seriously injured or interfere with safe operation of the mower.

Mowing in reverse is not recommended because it is difficult to maintain a clear vision of the mowing path. However, should it become necessary to back up, remember to look down and behind before andwhile backing.

6

WARNING

Failure to observe the following safety instructions could result in serious injury or death.

GENERAL OPERATION (continued):

Never leavea running mower unattended. Always turn off blades, set parking brake, stop engine and remove key before dismounting.

Turn off blades when not mowing. Injury could occur from contact with movingparts.

Under no circumstances should you place hands or feet under the mower deck or in the chute while blades or impeller arestillrunning.

Toavoidpersonalinjuryfromaccidentalclutchengagement, 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.

Slowdown before turningto reduce the risk of tip-over.

Watchfortrafficwhenoperatingnearorcrossingroadways.

Use extra carewhen loadingorunloading the mowerintoa trailer or truck. Push, do not ride the mower when loading and unloading.

7

WARNING

Failure to observe the following safety instructions could result in serious injury or death.

GENERAL OPERATION (continued):

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, areinvolved in a large percentage of ridingmower-relatedinjuries. These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and othersfrom seriousinjury.

To protect against possible tip-over,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.

8

WARNING

Failure to observe the following safety instructions could result in serious injury or death.

SLOPE OPERATION:

Slopes are a major factor related to loss-of-controlandtip-overaccidents, which can result in severe injury or death.

All slopes require extra caution. If you feel uneasy on a slope, do not mow it!

DO

Mow across the slope with your Dixon® ZTR® --never up or down. This will decrease the risk oftip-over.

Remove obstacles such as rocks, tree limbs, wires and other foreign objects that can be thrown by mowerblades.

Watch for holes, ruts, roots and bumps. Uneven terraincouldoverturnthe mower. Tall grass canhide such obstacles.

Use slow speed. Tires may lose traction on slopes even thoughthe brakes are functioning properly.

Avoid starting or stopping on a slope. If tires lose traction, disengage the blades and proceed slowly down the slope.

9

WARNING

Failure to observe the following safety instructionscould result in serious injury or death.

SLOPE OPERATION (continued):

DO (continued):

Keepallmovement on theslopesslowand gradual.

Do not makesudden changes in speed or direction.

Useextremecautionwhen operatingthemowerwith attachments to prevent tip-overorroll-over.

If front wheels lift off the ground, pull levers back to stabilizethe mower. Discontinue mowingtheslope!

10

WARNING

Failure to observe the following safety instructions could result in serious injury or death.

SLOPE OPERATION (continued):

DO NOT

Donotturnonslopesunlessnecessary,andthen, turn slowlyand graduallydownhill,if possible. Rapiduphill turns maycause tip-over.

Donotmowneardrop-offs,ditches,orembankments.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 onthe 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.

11

WARNING

Failure to observe the following safety instructions could result in serious injury or death.

FIRE HAZARDS:

Use extra carewhen handlinggasoline and other fuels. Theyareflammable and vapors areexplosive.

Store all fuel in approved containers specifically designed for that purpose.

Allow engine to cool before refueling. Never remove fuel cap or add fuel withengine running.

Do not smoke while refueling or operating the mower.

To reduce fire hazard, keep mower free of grass, leaves and other debris build-up.

If gasoline is spilled, do not attempt to start the engine. Move mower awayfrom 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.

Iffuelisspilledonclothing,changeclothingimmediately.

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.

12

WARNING

Failure to observe the following safety instructionscould 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 theframeor “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 nozzlelock-opendevice.

13

WARNING

Failure to observe the following safety instructions could result in serious injury or death.

CHILDREN:

Tragic accidents can occur if the operator is not alert to the presence of children.

Children are attracted to lawn mowers and the mowingactivity.

NEVER assume children will stay where they were last seen.

Be alertto avoid accidents.

Keep children out of the mowing area and under the watchfulcare of anotherresponsible adult.

Be alert and turn mower off if a child enters the area.

Before and during backing look BEHIND and DOWN forsmallchildren.

Never carry children.Theymayfalloff and be seriously injured or interfere with safe mower operation.

Never allow children to operate the mower.

Use extra carewhen approaching blind corners, shrubs, trees, or other objects that may obscure vision.

14

WARNING

Failure to observe the following safety instructions could result in serious injury or death.

SERVICE:

Never run a mower inside a closed area or without proper ventilation.

Keep nuts and bolts tight, especially blade attachment bolts, and keep equipment in good condition.

Never tamper with safety devices. 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 which could expose moving parts or allow objects to be thrown. Frequently check components. Replace with original equipment parts when necessary.

Mower blades are sharp and can cut. Wrap blades or wear gloves, and use extra caution when servicing them.

Batteries contain sulfuric acid. To prevent burns, avoid contact with skin, eyes and clothing.

15

DIXON® ZTR® PRO SERIES COMMERCIAL/RESIDENTIAL WARRANTY POLICY

Black Bear™, Kodiak™, Grizzly™ & SilverTip™ 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.COMMERCIALWARRANTY(useother than,orinadditionto,mowingatowner’s primaryplaceofresidence):

a.First two years - 100% parts andlabor subject to the conditions and limitations describedhereinwith the exceptionof non-covereditemsspecifiedbelow.

b.Third yearlimited to 100% parts cost as shownin the current Dixon® Parts Price List andsubject to the conditions and limitationsasdescribedherein.

c.AttachmentsmarketedthroughorapprovedbyDixonIndustries,Inc. arewarrantedforoneyear partsandlabor incommercial use applications.

d.ProSeriesModels arenotsubjecttohourmeterrestrictions.

e.Warrantyapplies tonewandunusedmowersandisnottransferable.

2.RESIDENTIALWARRANTY(usedonlyatowner’sprimaryplaceofresidence):

a.Threeyears100%partsandlaborsubjecttotheconditionsandlimitationsdescribedhereinforaperiodofthreeyearsfrom dateofpurchasebytheoriginalowner.

b.Attachments marketedthroughorapprovedbyDixonIndustries,Inc.,arewarrantedfortwoyears partsandlaborinresidential use applications.

c.Warrantyapplies tonewandunusedmowers andistransferable.

3.Lifetimewarrantyonallframesandleadingedgeofallfabricated(welded)decks.

4.All Dixon®warranty must be accomplished byauthorized Dixon®dealers andin accordance withDixon® warranty policy and allowances. All warranty claims must be submittedtoDixon Industries for approval.

5.Warranty laborreimbursementtodealersbasedonpublishedDixon® flatrateschedule.

6.Warrantydoesnotapply todamageintransitorincidentsofmisuse,negligence,accidents, oralteration. Theuseofpartsor components other thanthosesuppliedby DixonIndustriesVOIDSALLWARRANTY.

7.Battery warrantyislimitedtooneyearfromdateofmanufacture.

8.The following items are notcoveredby this warranty policy:

a.Routinemaintenanceoradjustments toincludeanyoils, filters orother fluids used.

b.Belts, blades andtires.

c.Pick upanddeliverycharges fortransportationofmowertoandfromanauthorizedDixon®dealer’s placeofbusiness.

d.Engines.Thesearecoveredunderaseparatewarranty byeachindividual enginemanufacturer.Consultenginemanual

for warrantydetails.

e. Any costs orexpenseofprovidingsubstituteequipmentwhilerepairworkisbeingperformedonawarrantedmower.

9.THEREISNOOTHEREXPRESS WARRANTY. TOTHE EXTENTPERMITTED BYLAW,ALLIMPLIEDWARRANTIES, INCLUDINGTHOSEOFMERCHANTABILITYANDFITNESSFORAPARTICULARPURPOSEAREEXCLUDED; OTHERWISE,ALLSUCHIMPLIEDWARRANTIESARELIMITEDTOTHESAME DURATIONANDREMEDIESASTHE EXPRESSWARRANTY. ALLLIABILITIESFORCONSEQUENTIALDAMAGESUNDERANYEXPRESSORIMPLIED WARRANTYAREEXCLUDED.

16

 

SPECIFICATIONS

 

BLACK BEAR™

CHASSIS:

11 GA - rectangular tube

SEAT:

Designed for operator comfort by use of high-density

 

closed cell foam padded back and arm rests, upholstered

 

with CorduraTM water-repellentfabric. Seat is adjustable

 

fore and aft.

MOWER DECK:

Made of 7 GA fabricated welded construction with external

 

reinforcement ribs. Two blades combine for a 34” cut

 

width. Cut height approximately 1.5” to 5.5” via 17 position

 

lift handle.

BLADE DRIVE:

Electric clutch

DRIVESYSTEM:

Each rear wheel is independently driven by a Parker 10cc

 

pump and TE0230 wheel motor.

ENGINE:

Each mower is powered with either a 16HP Kawasaki, or

 

18HP Kohler engine, overhead valve, air cooled, gasoline,

 

full pressure lubrication with oil filter.

STARTINGSYSTEM: Electric by key switch operation with safety interlocks on parking brake and blade drive clutch.

TIRES:

Front13 x 5 x 6 smooth tread (16-21lbs)

 

Rear 23 X 8.5 X 12 Turf Master (8-14lbs)

CAPACITIES:

Fuel - 4.5 gallon (approximately)

 

Hydrostat Oil tank - 4 quart with in-line25 micron filter

 

Engine - 2 qts. SAE 10W30 (with filter)

DIMENSIONS:

 

Kawasaki

Kohler

 

Width

35.5”

35.5”

 

Height

46”

46”

 

Length

71”

73”

 

Weight

625 lbs.

625 lbs.

Additional information may be provided elsewhere in this manual.

SPECIFICATIONS SUBJECT TO CHANGEWITHOUTNOTICE

17

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.

18

CONTROLS

CONTROL LEVERS

Note: For access to the seat, move control levers to neutral position and swing them outward.

TOGOFORWARD

•From neutralposition, gentlypush control leversforward.

•To increase speed, move levers further forward.

TO GO BACKWARDS

•From neutralposition, gentlypull control leverstoward you.

TURNING

•Turningis controlled bymovingonecontrol leverslightly forward or rearward of the other.

•To turn left, move left lever rearwardof the right lever. •To turn right, move right lever rearwardof the leftlever. •To turn on mower’s own axis (zero turningradius), 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.

19

CONTROLS

PARKING BRAKE:

The parking brake is designed to hold the mower from moving and is not intended foruse in stoppingthe mower while it is in motion. The engine will stop if the parking brake is engaged while the control levers are in the drive position.

CAUTION Engage parking brake

before starting engine.

TO SET PARKING BRAKE:

The hand operated parking brake is located on the left hand side of the mower.

To engage brake, pull lever up (to the rear).

To release brake, movelever forward (down).

Note: Always set parking brake before dismounting.

Releaseparking brake beforemoving mower.

20

CONTROLS

MOWER DECK CUT HEIGHT LIFT LEVER:

Located to the right and front of the operator.

Controls the cutting height.

17 positions of adjustment

Depress trigger and move lever forward to lower deck.

Pull lever back to raise deck.

Set desired cut height with pin.

Use foot pedal to assist with raising and lowering deck.

Note: Always use high position for transport.

The two holes at the front of the quadrant are for 1-1/2”and1-3/4”cut heights.

The four holes along the bottom of the quadrant are for one inch cut height increments (2” to 5”).

The second row of holes from the bottom are for an additional 1/4” of cut height over its mating one inch increment (2-1/4”to5-1/4”).

The third row of holes from the bottom are for an additional 1/2” of cut height over its mating one inch increment (2-1/2”to5-1/2”).

The remaining three holes are for an additional 3/4” of cut height over their mating one inch increments (2-3/4”to4-3/4”).

21

CONTROLS

BLADE DRIVE:

•Located on the control panel, on operator’s right.

•To engage the mower blade, pull up on the switch.

•To disengage mower blade, push down.

CIRCUIT BREAKER:

•Locatedonthecontrolpaneltotheoperator’s right.

•Protection of the electrical system is by (1) 15 amp circuit breaker.

•If circuitbreaker trips, push button to reset. •If this condition repeats, consult dealer for inspection and repair.

CHOKE AND 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 insure adequate cooling of the engine and to maintain mower deck blade speed while mowing.

22

OPERATION INSTRUCTIONS

The safe and successful operation of the BLACK BEAR™ will depend upon the operator having the correct knowledge of all controls used on the mower and making good judgements about the terrain to be mowed.

NEVER allow anyone to operate the mower without completeknowledgeofallcontrolsandtheirfunctions.

Duringinitialoperation, “learningtodrive”,set throttle at slow speed.

Sound judgement bythe operatorwill prevent accidents.

BEFORE OPERATING MOWER:

1.Read engine manufacturer’s operatingand maintenanceinstructions.

2.Read and observe allsafetyinstructions on your mower and inthemanual.

3.Check engine oil.

4.Check fuel cap to be sure it is in place.

5.Be sure parking brake is on.

6.Be sure mower blade drive is off.

7.Know howto stop engine. (Turn keyto off position).

23

OPERATION INSTRUCTIONS

CAUTION Failure to follow these instructions may result in personal injury.

STARTING INSTRUCTIONS:

1.Parking brakemust be on, control levers in outward position and blade drive disengaged.

2.Position throttle to desired speed setting. If engine is cold, position throttle lever in the “choke” position.

NOTE: Engine may require partial choke setting to start evenif theenginehas been operatedfor 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 parking brake.

7.Swing levers inward.

8.Operate mower per “CONTROL” instructions on Page 19.

CAUTION Donot operatetheenginein 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

TESTING OF SAFETY INTERLOCK SYSTEMS:

Failure to observe the following testing instructions could result in serious injury or death.

The following tests should be performed at the start of each mowing day.

PARKINGBRAKESWITCHTEST:

a)Swing control levers to outward position

b)Disengage blade drive switch

c)Put parking brake in OFF position

d)Turnignitionswitch to START

Engine should not turn over or attempt to start.

CONTROLLEVER SWITCHTEST:

a)Disengage blade drive switch

b)Put parking brake in ON position

c)Swingcontrol levers inward

d)Turnignitionswitch 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.

25

OPERATION INSTRUCTIONS

TESTING OF SAFETY INTERLOCK SYSTEMS:

Failure to observe the following testing instructions could result in serious injury or death.

The following tests should be performed at the start of each mowing day.

BLADE DRIVE SWITCHTEST:

a)Put parking brake in ON position.

b)Swing control levers to outward position.

c)Engage blade drive switch.

d)Turn ignition switch to START.

Engine should not turn over or attempt to start.

SEAT SWITCHTEST:

a)In a SAFE AREA away from bystanders, start the engine.

b)Leave control levers in outward position and put parking brake ON position.

c)Engage blade drive.

d)Raise slightlyoff 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.

26

OPERATION INSTRUCTIONS

MOWING WITH A MULCHING ATTACHMENT:

Mulching or recycling the grass clippings requires a totally different mowingapproach thanwould 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 mulchingtipslisted below:

1.Read and follow the installationinstructionsthatare includedwith yourmulcher.

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 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 engineto stall.

4.It may be necessaryto cut the lawn twice to achieve acceptable mulchingperformance 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 verypoor in wet grass conditions.

6.Maintain sharp blades throughout the cutting season.

Thisis very important. Optimal mulching performance cannot be obtained with a dull or nicked up blade.

27

OPERATION INSTRUCTIONS

MOWING WITH A MULCHING ATTACHMENT (continued):

7.Keep the underside of the mower deck clean.

Remove all grass and dirt build-upfrom 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. Thiswill evenlydisperse the mulched grass clippings over the lawn for even fertilization.

If the mulching qualityof the mower doesnot seem to be satisfactory, tryone or more of the following tips:

a.Raise the height-of-cutsettingon your mower.

b.It may be necessaryto cut your grass morefrequently.

c.Operate the mower at a slower ground speed.

d.Overlap cutting swathsinsteadof cutting a full swath with each pass.

e.Mow across the marginal areas a second time.

f.CUT HIGHMOW OFTEN!

28

OPERATION INSTRUCTIONS

MOWING WITH A GRASS CATCHER ATTACHMENT:

In order to achieve optimum performancewhen mowing with a grass catching attachment, please read and follow the tips listed below.

1.Read and follow the installationinstructions thatare included withyour 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 bagsoftento preventplugging.

4.If the grass is tall, place the mower deck cut height selectorin the top or second notch. “Initially”overlap cuttingswathsinstead 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 mowingwithout a grasscatching attachment.

29

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.Use of grass catchers requires 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.

Failure to observe the following instructionsWARNING may 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.

30

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 theTroubleshootingguide.

CAUTION To avoid personalinjury, be surethatthe 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 cuttingswaths 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.

31

OPERATION INSTRUCTIONS

GRASS HEIGHT & CUTTING SUGGESTIONS:

Do not attempt to cut grass when it is wet.

If the grass is tall, place the mower deck cut height lever in the top or second notch. “Initially” overlap cuttingswaths 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 bladesthroughout thecutting season.

As a ruleof thumb,never cut off more than1/3 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 on adequate moistureconditions and normal thatch build-upin a healthy lawn. Some locations and applications may require slightlydifferentcutheights. If in doubt,consult your local lawn professional for assistance.

GrassTypes

Best Cut Heights

Bermudagrass

1 - 2”

Bluegrass

2 - 3”

Buffalograss

11/2 -3”

Ryegrass

2 - 3”

Tall Fescue

3-31/2

Zoysiagrass

1 - 3”

32

OPERATION INSTRUCTIONS

TOWING TRAILERS AND OTHER ATTACHMENTS:

Towing a trailer or other attachment that is too heavy could damage the drive or cause the mower to become unstable. Limit loads to 250 pounds or less with this mower.

TO FREE WHEEL MACHINE (Unlock Transmission):

Always turn off engine before engaging or disengaging the hydro release (free wheel) lever. Never attempt to move the lever with the engine running.

The hydro release valves are located below the seat, on the front side of the hydro pumps. To access the release valves, lift the seat frame assembly, use a 5/8” wrench to rotate boltcounter-clockwisetwo full turns to disengage pump. Repeat procedure for opposite pump. To engage, rotate each pump bolt clockwise until bolt is snug.

NOTE: Before pushing or towing tractor, transmission must be unlocked and parking brake released. The tractor should never be pulled at more than 2 miles per hour or for any appreciable distance.

33

CARE AND MAINTENANCE

WARNING

Failure to observe the following instructions may result in personal injury.

Before performing any maintenance, turn off engine, allow to cool & remove key.

Use extreme care when working on machinery. Donot wearwatch orjewelry.

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)every50 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 oil & oil filter..........

(100 hours break-in)every500 hours

34

CARE AND MAINTENANCE

CUTTER BLADE MAINTENANCE:

CAUTION Stop engine and remove ignition keyfor safety. Wear heavy, thick gloves when holdingontocutter 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. 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. Refer to diagram. Tighten blade bolt to 60 ft. lbs.

Blades should be discarded when worn excessively.

 

DANGEROUS!

 

DO NOT USE

New Blade

BLADE IN THIS

CONDITION!

 

 

When notch starts,

 

discard blade

35

CARE AND MAINTENANCE

ENGINE:

For complete maintenance and operating information of the engine, please referto the maintenance instructions furnished bytheengine manufacturerincludedinyour ZeroTurnRadius mower information packet.

CAUTION

Battery contains sulfuric acid electrolyte which

is poisonous and corrosive.

BATTERY:

Thisis a maintenance-freebatteryand the fluid level cannot be checked.

•Charge battery if required.

OFF SEASON BATTERYSTORAGE: •DO NOT remove batteryfrom mower.

•Clean top of battery and terminals with baking soda andwater.

•Identify each cable so they can be reconnected to the correctterminal.

•Disconnect cables from terminals. ALWAYS disconnect ground cable first and reconnect last.

•Chargebattery.

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 inactivityand

 

mayprevent premature batteryfailures. Contact your

 

dealer for moreinformation.

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.

Fronttires

13 x 5.00 - 6

16-21lbs.

Rear tires

23 x 8.5 - 12

8-14lbs.

Lug nuts or lug bolts should be checked regularly for tightness.

LUBRICATION:

CHASSIS:

grease zerks

LOCATIONS:

front wheels

 

front castertubes

 

control lever pivots

 

mower deck hubs

 

deck lift shafts

 

deck trailer arms

 

brake shafts

SERVICE INTERVALS:

Every 50 hours of operation or

 

once per season.

RECOMMENDED

Name brand wheel bearing

GREASE:

or multi-purposegrease

 

(3 pumps each)

37

CARE AND MAINTENANCE

BELTS:

Check belts every 50 hours. Replace any belts found to be in poor condition.

BELT TENSION:

Engine to Mower Deck Belt: P/N 10669

Manual adjustment. Turnnut on deckeyebolttoadjust belttension.

Note: Belt deflection or movementshould be approximately 1/4”when measured at mid-pointbetween pulleys. Periodicallyinspect both belt and idler systems.

38

CARE AND MAINTENANCE

CAUTION HOT oil maycause burns. Allow engine to cool before draining oil.

CHANGING THE ENGINE OIL:

1.The “Dapco” oil drain valve is located on either side of the engine crankcase(depending on the type of engine installed on yourZTR®).

2.Place a suitable containerunder the drain valve hose.

3.To drain, turn hexheadvalve stem counter-clockwisewith a 10mm wrench or socket. Open to full open (approximately7 turns).

4.After engine is drained, tighten hex stem.

5.Change oil filter.

6.Fill with oil (see steps on next page).

NOTE: Refer to engine manufacturer’s recommendations for frequencyof oil changes.

HexHead Valve

Stem

39

CARE AND MAINTENANCE

CAUTION

OIL FILL:

HOT oil maycause burns. Allow engine to cool before draining oil.

1.Clean any spilled oil from engine and chassis.

2.Refill engine with type, and quantity of oil recommended bythe enginemanufacturerin engine literature.

NOTE: Engine oil changes on the BLACK BEAR™ will require replacement of the oil filter. These filters may be available from your local Dixon® Dealer.

OIL FILTERS:

1.Replace filter each time the oil is changed.

2.Oil Filters can be obtained from your authorized engine dealer.

3.The use of any other oil ftiler may cause damage to the engine.

PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS.

PROTECT YOUR ENVIRONMENT.

40

CARE AND MAINTENANCE

HYDROSTATIC TRANSMISSION FLUID &

FILTER SERVICE:

Dirt or water in fluid can ruin the hydrostatic transmissions.

SERVICE INTERVALS:

1.Initial filter service - 100 hours

2.Every 500 hours or once a year thereafter.

RECOMMENDED FLUID:

All temperatures -

Dixon Blue™ 15W-50Synthetic Hydrostatic Fluid

~or if not available~

Normal Operating Temperatures - 20W50 engine oil Cold climate usage - 10W40 engine oil

Use engine oil with an API classification of SG/CD.

Dixon Blue™ 15W-50Synthetic Hydrostatic Fluidis specifically formulated to provide excellent all-climate performance and extended time between oil changes.

FLUIDFILTER: P/N 18045IMPORTANT

The fluid filter is a special design for use on “vacuum or suction” oil flow systems.

DO NOT USEAUTOMOTIVE ENGINE OILFILTERS!

These filters require a “pressure” to allow oil flow. Usage will result in an “air-lock”condition with possible damage.

41

CARE AND MAINTENANCE

HYDROSTAT OIL MAINTENANCE PROCEDURE:

Checkthe oillevelin hydrostatic transmisisonoil reservoir afterevery25 hoursof usage. Clean the oilreservoir cap andtheareaarounditpriortoremoval.Checktheoillevel. Oil should be approximately 1/4” below top of oil tank baffle. Replenish as needed with Dixon BlueTM 15W-50Synthethic Hydrostatic Fluid or a quality SAE20W-50motor oil. DO NOT OVERFILL. When checking the oil level, be verycareful to keep the reservoir clean.

Changetheoil inthereservoirandhydrostattransmission oil filter after the first 100 hours of use. Then every 500 hours after that. Remove the filterand be sure all oil has drainedfromthereservoir. Replacewitha newOEM filter (P/N 18045) and Dixon BlueTM 15W-50Synthetic Hydrostatic Fluid or a quality SAE20W-50motor oil.

Please dispose of used oil at proper collection centers. Protect your environment

42

CARE AND MAINTENANCE

NEUTRAL ADJUSTMENT

1.Liftseat.

2.Blockuptheunitsothatthedrivewheelsareoff the ground.Removereartires.

3.Loosen jam nuts on both ends of the control rod coupler. Note: The rear jam nuts are left hand threads.

4.With steering control arms in the “out” neutral position, start the engine and run atfast idle.

5.Adjusttheneutralpositionbyturningthecontrolrod coupleruntilthehubsdonotrotate.

6.Re-tightenthe jam nuts against the control rod couplerandchecktoseethatthedrivewheelsare notturning.

7.Repeat steps 3-6for the other side.

8.Shut off engine before reinstalling rear tires and removingtheblocks.

43

CARE AND MAINTENANCE

MOWER DECK LEVELING PROCEDURE:

There are a total of (4) slots which will control the attitude orpitchof themowerdeck. Deckshouldbelevelorpitched slightly higherin rear.

A.Placethe moweronasmooth levelsurface withfront casterspositionedtowardsdeck. Checktirepressures toinsurethemowerhasacorrectstance.Inflatetiresas required:

Front

16 - 21 lbs maximum

Rear:

8-14lbsmaximum

NOTE: Toinsureaccuracyoflevelingprocedure,mower deckdrivebeltmustbeinstalledpriortoleveling deck.

B.Wearheavygloves. Turn each outer blade tipto align with the deck or in a side-to-sidemanner.

C.Measurefrom thefloorsurface up tothebottom ofthe blade tip on the discharge side of the mower deck. Retain this measurement. Movetothe opposite side, checkthatmeasurementisthesame. Ifadjustmentis required,loosenthelocknutandmovemountingboltup ordowninslotuntilbothside-to-sidemeasurementsareequal. Retainmeasurement.

44

CARE AND MAINTENANCE

MOWER DECK LEVELING PROCEDURE (continued):

D.Turnbothouterbladestoalignwiththedeckinfront- to-rearmanner.Repositionrearmountingboltsup ordownuntilrearofmowerdeckispositionedlevel to 1/8” higher in the rear than theside-to-sidemeasurement.

E.Confirm measurements once again. Blade tips shouldbelevelinaside-to-sidemanner.Intherear,bladetipsshouldbelevelto1/8"higherthanside-to-sidemeasurement.Inthefront,bladetipsshould be level to 1/8" lower thanside-to-sidemeasurement.

NOTE: This will place the mower deck in a base measurementposition. Additionaladjustmentmay be required to achieve desired cut for the type of grass or conditions being mowed.

45

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 anywaterthatmayhave accumulatedin bearings, pulleysorfans.

Note:

Allowmower to cool before washing. If

 

bearingsare hot, they willdrawmoisture

 

inside as they dry and cause corrosion.

SERIAL NUMBERS:

The serial number is located on frame at rear of engine.

WARRANTY:

Referto warrantyinformation (pages 16).

PARTS/SERVICE:

See your Dixon® dealer for replacement parts, warranty or service.

46

CARE AND MAINTENANCE

MOWER DECK REMOVAL:

1.Remove mower deck drivebelt from clutch. To relieve belt tension, loosen nut on tensioner eyebolt.

2.Move deck into lowest cut position and support deck withblocks.

3.Remove nut from each of the four hanger bolts (suspended from chains). Remove hanger bolts from deck slots.

4.Removehardwareattachingtrailerarmstorearofdeck.

5.Slide deck from beneath chassis.

6.Reverse procedure to re-installdeck to chassis.

47

TROUBLESHOOTING

1. ENGINE WON’T TURN OVER

Mower blades engaged- - - - - - - - - - - - - - - - - - - disengage blades Parking brake not on- - - - - - - - - - - - - - - - - - engage parking brake Circuit breaker trips- - - - - - - - - - - - - - - - - - - - - - - - -resetbreaker 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- - - - - - - - - - - - - - -drainoldfuel-replacewith new fuel Clogged fuel line- - - - - - - - - - - - - - - - - - - - - - - - - - check fuel filter Fuel tank vent plugged- - - - - - - - - - - - - - - - - - - - --cleanfuel vent Faulty fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer

5. ENGINE OVERHEATED

Air intake screen or fins clogged- - - - - -cleanintake screen and fins Oil level too low or too high- - - - - - - - - - - - - - - - - - --adjustoil level Running engine too slow - - - - - - - - - - - - - - - - --runengine faster

48

TROUBLESHOOTING

6. ENGINE RUNS BUT MOWER WON’T MOVE FORWARD

Drive belt broken or slipping- - - - - - - - - - - - - - - - replace drive belt Transmission oil low- - - - - - - - - - - - - - - - - - - - - - - - - - - - add oil Damaged transmission- - - - - - - - - - - - - - - - - - - - - -consultdealer Transmissionby-passmay be engaged- - - - disengage(see page 32)

7. MOWERLOSESPOWERORTRANSMISSIONOVERHEATS

Engine air filter--- - - - - - - - - - - - - - - - - - - - - - - - - clean or replace Transmission damage- - - - - - - - - - - - - - - - - - - - - --consultdealer

8. ENGINE STALLS WHEN BLADES ARE ENGAGED

Operator not on seat- - - - - - - - - - - - - - - - - - - - - - - - - -siton seat Faulty interlock system- - - - - - - - - - - - - - - - - - - - - - consult dealer Fauty 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- - - - - - -checktire inflation/adjust control linkage Mower creeps in neutral- - - - - - - - - - - - - - - - adjust control linkage Low on power- - - - - - - - - - - - - - - - - - - - - - - - --checkbelt tension

10. CUT QUALITY

Cut uneven left to right- - - - - - - - - - - -checktire inflation/level deck Ends of grass blades are ragged- - - - - - - - - - - - - - sharpen blades Poor dispersal of grass- - - - - - - - - - clean deck/check for loose belt Skips in spots- - - - - - - - - --checkfor loose belt/slow ground speed

49

STANDARD SERVICE PARTS LIST

Blades

*Standard Lift Fusion - 10614

Hi Lift Fusion - 10954

Lo Lift Fusion - 10972

Gator Fusion - 10615

*Factoryinstalled

Belts

Engine to Mower Deck - P/N 10669

Engine to Hydros - P/N 10923

ENGINE AIR AND OIL FILTERS

Refer to Engine Operator’s Manual for correct service intervals for engine oil changes and air filter maintenance.

Protect yourengineinvestment, useonly original equipment filters. Refer to the Engine Operator’s Manual or ask your dealer for correct replacement parts.

50

OWNER’S INFORMATION

Date of Purchase

Mower Model Number

Mower Serial Number

PurchasedFrom

Name

Address

DATE OIL CHANGED

DATE ENGINE TUNED

Dixon Industries, Inc.~P.O. Box 1569~Coffeyville, Ks~620-251-2000~Fax620-251-4117

Dixon® and ZTR® are registered trademarks of DixonIndustries,Inc.

The engine exhaust from this product contains

WARNING: chemicals known to the State of California to cause

cancer, birth defects or other reproductive harm.

DIXONINDUSTRIES,INC.

 

P.O. Box 1569

 

Coffeyville,Ks 67337-0945

BLACK BEAR™

620-251-2000

Part No.11249-0605