Dixon Speedztr 44-968999538, 36 968999539, 42-968999546, 44-968999547 User Manual

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SPEEDZTRZTR®

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-relatedinjuries. 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-of-control andtip-overaccidents, 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 oftip-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-overorroll-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 nozzlelock-opendevice.

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 (SPEEDZTR36 & 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

Chassis:

Body:

Mower Deck:

Blade Drive:

Transmission:

Engine:

Starting

System:

Tires:

Capacities:

Dimensions:

SPECIFICATIONS

SpeedZTR™ 36 Model 968999539

" x 2" rectangle tubular side frame

Body parts are made of steel

36" (91cm) 11 gauge fabricated construction with reinforced ribs.

Electric clutch

Each rear wheel is independently driven by a Hydro Gear EZT hydrostatic drive with cooling fan.

16.5 HP Briggs & Stratton Intek, 4-cycle,single cylinder, overhead valve,air-cooled,gasoline, vertical shaft, cast iron cylinder, full pressure lube withspin-onfilter

Electric-keyswitch operation with safety interlocks on park brake, steering levers and blade drive.

Front 11 x 4.00-5smooth tread

16-21PSI

 

(110-145kPa)

Rear 18 x 7.50-84-plyturf tread

8-14PSI

 

(55-97kPa)

Fuel

4.5 gallon (17 liters)

Engine Oil

1.3 quarts (1.3 liters)

Width

43" (109 cm) maximum track width

Height

43" (109 cm) to top edge of seat

Length

69" (175 cm) hitch tab to front

Weight

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:

" 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-onfilter

 

Starting

Electric-keyswitch operation with safety interlocks

System:

on park brake, steering levers and blade drive.

Tires:

Front 11 x 4.00-5smooth tread

16-21PSI

 

 

(110-145kPa)

 

Rear 18 x 8.50-84-plyturf tread

8-14PSI

 

 

(55-97kPa)

Capacities:

Fuel

4.5 gallon (17 liters)

 

Engine Oil

1.3 quarts (1.3 liters)

Dimensions:

Width

43" (109 cm) maximum track width

 

Height

43" (109 cm) to top edge of seat

 

Length

69" (175 cm) hitch tab to front

 

Weight

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:

" 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

Electric-keyswitch operation with safety interlocks

System:

on park brake, steering levers and blade drive.

Tires:

Front 11 x 4.00-5smoothtread16-21PSI

 

 

(110-145kPa)

 

Rear 18 x 9.50-84-plyturf tread8-14PSI

 

 

(55-97kPa)

Capacities:

Fuel

4.5 gallon (17 liters)

 

Engine Oil

1.3 quarts (1.3 liters)

Dimensions:

Width

43" (109 cm) maximum track width

 

Height

43" (109 cm) to top edge of seat

 

Length

69" (175 cm) hitch tab to front

 

Weight

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:

" 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, air-

 

cooled, gasoline, vertical shaft, full pressure lube

 

with air filter, aluminum head and block withcast

 

iron cylinder liners

Starting

Electric-keyswitch operation with safety interlocks

System:

on park brake, steering levers and blade drive.

Tires:

Front 11 x 4.00-5smoothtread16-21PSI

 

 

(110-145kPa)

 

Rear 18 x 9.50-84-plyturf tread8-14PSI

 

 

(55-97kPa)

Capacities:

Fuel

4.5 gallon (17 liters)

 

Engine Oil

1.3 quarts (1.3 liters)

Dimensions:

Width

43" (109 cm) maximum track width

 

Height

43" (109 cm) to top edge of seat

 

Length

69" (175 cm) hitch tab to front

 

Weight

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

Fig.2

operator’s left.

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

•To release brake, move lever forward (down).

NOTE: Always set park brake before dismounting.

Release park brake before moving mower.

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

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.

Choke

Position

Maximum

Throttle

Setting

P

U

SH

BLADE

DRIVE

STOP

15

ET

TO RES

CHOKE CONTROL

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.

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

Fig.3

CHOKE

BLADE

DRIVE

THROTTL

STOP

15

P

 

U

ET

S

H TO RES

Fig.4

21

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 brakeor 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 Fig. 4release levers outward so

they return to normal position.

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-cutsetting 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

Best Cut Heights

Bermudagrass

1 - 2"

(25-51mm)

Bluegrass

2 - 3"

(51-76mm)

Buffalograss

-3"(38-76mm)

Ryegrass

2 - 3"

(51-76mm)

Tall Fescue

3-3½"

(76-89mm)

Zoysiagrass

1 - 3"

(25-76mm)

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-inand

.....................................

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:

Tighten to:

36",44"

50-60ft. lbs.(68-81Nm)

42"

35 ft. lbs. (48 Nm)

 

 

Blades should be discarded when worn

New blade

 

When notch starts,

Fig.7

discard blade

36" and 44"

50-60ft. lbs.(68-81Nm)

Fig.5

42"

35 ft. lbs. (48 Nm)

Fig.6

DANGEROUS! Do not use blade in this condition!

35

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-freebattery 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

11 x 4.00 - 5

16-21

PSI

(110-145kPa)

Rear tires 36"

18 x 7.50 - 8

8-14

PSI

(55-97kPa)

Rear tires 42"

18 x 8.50 - 8

8-14

PSI

(55-97kPa)

Rear tires 44"

18 x 9.50 - 8

8-14

PSI

(55-97kPa)

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

LUBRICATION

CHASSIS:

(9) grease zerks

LOCATIONS:

(2) front wheel axles

 

(2) front wheel casters

 

(2) deck lift shaft

 

(2) control levers

 

(1) mower deck hub

SERVICE INTERVALS:

Every 50 hours of operation or

 

once per season.

RECOMMENDED

Name brand wheel bearing

GREASE:

or multipurpose grease

 

(3 pumps each)

Caster/Axle

Lift Shaft

Control Levers

 

Fig.8

 

37

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-clockwisewith 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-pointbetween 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-clockwiseuntil neutral is achieved (clockwise for left side). If right wheel is creeping backward, turn coupler clockwise until neutral is achieved(counter-clockwisefor 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 (110-145kPa)

Rear

8

- 14

PSI (55-97kPa)

2.Put the mower deck in the mid-rangecut 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-Rodsfrom lift arms.

5.Remove hairpin cotter from top of rear L-Rods(2 places) and detachL-Rodsfrom 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-LiftFusion

P/N 539 118672

Standard Lift Fusion

P/N 539 115536

Standard Lift

P/N 539 115242

Hi-LiftGator Fusion

P/N 539 118673

Gator

P/N 539 125846

Transmission Belt

P/N 539 120772Deck Belt P/N 539 117811

42" Deck

Blade

 

 

* Hi Lift Fusion

P/N 539 119843

 

Hi-Lift-

P/N 539 119851

 

Transmission Belt

P/N 539 120772

Deck Belt P/N 539 122734

 

44" Deck

Blade

 

* Hi Lift Fusion -

P/N 539 119836

Super Hi-LiftFusion -

P/N 539 119798

Standard Lift Fusion - P/N 539 119860

Gator Fusion -

P/N 539 119862

Hi-Lift-

P/N 539 119858

Standard Lift -

P/N 539 119859

Transmission Belt

P/N 539 120772Deck Belt P/N 539 118156

*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-replacewith 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~Fax402-223-1053

Dixon and ZTR®

are registered trademarks of Dixon

! WARNING The engine exhaust from this product contains chemicals known to the State of

California to cause cancer, birth defects or other reproductive harm.

DIXON

SpeedZTR 36/42/44

401 Commerce Street

Part No. 539 121042R1

Beatrice, NE 68310

10/04/06