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KODIAK ELS 60
User Manual
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Dixon KODIAK ELS 60 User Manual

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KODIAK® ELS-60
Safety Instructions
&
Operator’s Manual
IMPORTANT - READ CAREFULLY
The information contained in this manual applies to all Dixon® Kodiak® ELS-60 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
SEAT ADJUSTMENT.........................................18
CONTROLS..................................................19-21
OPERATION INSTRUCTIONS....................22-32
CARE & MAINTENANCE............................33-47
TROUBLESHOOTING..................................48-49
STANDARD SERVICE PARTS LIST...............50
KODIAK® ELS-60 Part Number 11806-106
3
SAFETY
RIDING LAWN MOWERS,
IF IMPROPERLY OPERATED
CAN CAUSE SERIOUS INJURY OR DEATH
Pictured below are the most common causes of injury to the operator or bystander. Please read and understand this manual to prevent injuries.
Blade Contact
Run Over
Tip 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
WARNING
Failure to observe the following safety instructions
could result in serious injury or death.
GENERAL OPERATION:
Read, understand, and follow all instructions in this manual and on the mower before starting.
Only allow responsible adults, who are familiar with the instructions, to operate the mower.
Clear the area of objects such as rocks, toys, wire, etc., 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.
Be aware of the mower discharge direction and do not point it at anyone. Mower blades can throw rocks or other debris.
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. 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 backing.
6
and while
WARNING
Failure to observe the following safety instructions
could result in serious injury or death.
GENERAL OPERATION (continued):
Never leave a 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 moving parts.
Under no circumstances under the mower deck or in the chute while blades or impeller are still running.
To avoid personal injury from accidental clutch engage­ment, stop engine before removing grass catcher or unclogging chute.
Mow only in daylight or good artificial light.
Do not operate the mower while under the influence of alcohol or drugs.
Slow down before turning to reduce the risk of tip-over.
Watch for traffic when operating near or crossing road­ways.
Use extra care when loading or unloading the mower into a trailer or truck. Push, do not ride the mower when loading and unloading.
should you place hands or feet
7
WARNING
Failure to observe the following safety instructions
could result in serious injury or death.
GENERAL OPERATION (continued):
Never dismount mower without applying parking brake
or
stopping engine.
Protect your eyes. Always wear safety goggles or safety glasses with side shields when operating mower.
Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mower­related injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury.
To protect against possible tip-over, follow the manufacturer’s recommendation for wheel weights, counterweights and R.O.P.S.
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-control
and tip-over accidents, 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 of tip-over.
Remove obstacles such as rocks, tree limbs, wires and other foreign objects that can be thrown by mower blades.
Watch for holes, ruts, roots and bumps. Uneven terrain 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.
9
WARNING
Failure to observe the following safety instructions
could result in serious injury or death.
SLOPE OPERATION (continued):
DO (continued):
Keep all movement on the slopes slow and gradual. Do not make sudden changes in speed or direction.
Use extreme caution when operating the mower with attachments to prevent tip-over or roll-over.
If front wheels lift off the ground, pull levers back to stabilize the mower. Discontinue mowing the slope!
When operating on slopes over 15 degrees, the unit must be equipped with an approved, dealer­installed R.O.P.S. and Seat Belt Kit.
R.O.P.S. should be in the upright, operating position (not folded-down) at all times when operating mower.
Always use seat belt on any mower equipped with a R.O.P.S.
10
WARNING
Failure to observe the following safety 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. The mower could suddenly turn over if a wheel is over the edge of a cliff or ditch or if an edge caves in.
Do not mow on wet grass. Reduced traction could cause sliding.
Do not try to stabilize the mower by putting your foot on the ground.
Do not use grass catcher or other attachments on steep slopes (over 15 degrees). 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 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 build-up.
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.
12
WARNING
Failure to observe the following safety instructions
could result in serious injury or death.
FIRE HAZARDS (continued):
To prevent fire or explosion, keep sparks and open flames away from battery.
Keep electrical connections clean and tight. Inspect them often. Loose connections and corrosion increase fire risk.
Before disconnecting the negative ground cable, make sure all switches are off. This decreases the chance of sparking and fire.
Use care when backing to avoid pushing the grass bags into the frame or “hot” exhaust muffler of the engine. Fire could result.
To prevent fire and explosion caused by static electricity:
Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling.
When practical, remove fuel powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, refuel such equipment on a trailer with a portable container, rather than from a fuel dispenser nozzle.
If a fuel dispenser nozzle must be used, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not
use a nozzle lock-open device.
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
mowing activity.
NEVER assume children will stay where they
were last seen.
Be alert to avoid accidents.
Keep children out of the mowing area and under the watchful care of another responsible adult.
Be alert and turn mower off if a child enters the area.
Before and during backing look BEHIND and DOWN for small children.
Never carry children. They may fall off and be seriously injured or interfere with safe mower operation.
Never allow children to operate the mower.
Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.
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
®
Kodiak
DIXON® WARRANTS ITS ZTR® MOWERS AGAINST DEFECTS IN MATERIAL AND WORKMANSHIP
FOR THE PERIODS SET FORTH BELOW. THE SOLE REMEDY UNDER THIS WARRANTY IS
REPLACEMENT OR REPAIR OF PARTS INCLUDING LABOR COSTS.
THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS AND LIMITATIONS:
1. COMMERCIAL WARRANTY (use other than, or in addition to, mowing at owner’s primary place of residence): a. One year - 100% parts and labor subject to the conditions and limitations described herein
with the exception of non-covered items specified below.
b. Attachments marketed through or approved by Dixon Industries, Inc. are warranted for one year
parts and labor in commercial use applications. c. Pro Series Models are not subject to hour meter restrictions. d. Warranty applies to new and unused mowers and
2. RESIDENTIAL WARRANTY (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. Attachments marketed through or approved by Dixon Industries, Inc., are warranted for two
years parts and labor in residential use applications.
c. Warranty applies to new and unused mowers and
3. Lifetime warranty on all frames and leading edge of all fabricated (welded) decks.
4. All Dixon® warranty must be accomplished by authorized Dixon® dealers and in accordance with Dixon® warranty policy and allowances. All warranty claims must be submitted to Dixon Industries for approval.
5. Warranty labor reimbursement to dealers based on published Dixon® flat rate schedule.
ELS-60 Mower
is transferable.
is transferable.
6. Warranty does not apply to damage in transit or incidents of misuse, negligence, accidents, or alteration. The use of parts or components other than those supplied by Dixon Industries VOIDS ALL WARRANTY.
7. Battery warranty is limited to one year from mower manufacture date.
8. The following items are not (a) Routine maintenance or adjustments to include any oils, filters or other fluids used. (b) Belts, blades, tires and cosmetic appearance (paint, seat fade, etc.) (c) Pick up and delivery charges for transportation of mower to and from an authorized
Dixon® dealer’s place of business.
(d) Engines. These are covered under a separate warranty by each individual engine
manufacturer. Consult engine manual for warranty details.
(e) Any costs or expense of providing substitute equipment while repair work is being
performed on a warranted mower.
9. THERE IS NO OTHER EXPRESS WARRANTY. TO THE EXTENT PERMITTED BY LAW, ALL IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXCLUDED; OTHERWISE, ALL SUCH IMPLIED WARRANTIES ARE LIMITED TO THE SAME DURATION AND REMEDIES AS THE EXPRESS WARRANTY. ALL LIABILITIES FOR CONSEQUENTIAL DAMAGES UNDER ANY EXPRESS OR IMPLIED WARRANTY ARE EXCLUDED.
covered by this warranty policy:
16
SPECIFICATIONS
KODIAK® ELS-60
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 Cordura fore and aft. Mounted on operator suspension system.
MOWER DECK: Made of 11 GA fabricated welded construction with external
reinforcement ribs. Three blades combine for a 60” cut width. Cut height approximately 1.5” to 5” via 12 position lift handle.
BLADE DRIVE: Electric clutch
DRIVE SYSTEM: Each rear wheel is independently driven by a Parker 10cc
pump with fan and TE0230 wheel motor.
ENGINE: Each mower is powered with a 26 HP Briggs & Stratton
ELS twin cylinder engine, overhead valve, air cooled, gasoline, full pressure lubrication with oil filter.
STARTING SYSTEM: Electric by key switch operation with safety interlocks on
parking brake and blade drive clutch.
TM
water-repellent fabric. Seat is adjustable
TIRES: Front 13 x 5 x 6 smooth tread (16-21 lbs)
Rear 20 X 12 X 10 Turf Master (8-14 lbs)
CAPACITIES: Fuel - 11 gallon (approximately)
Hydrostat Oil tank - 4 quart with in-line 25 micron filter Engine - 2 qts. SAE 10W30 (with filter)
DIMENSIONS: Width 46” outside rear wheel measurement (approximate) Height 46.5”
Length 75” Weight 760 lbs.
Additional information may be provided elsewhere in this manual.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
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.
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.
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 for use in stopping the 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, move lever forward (down).
Note: Always set parking brake before dismounting.
Release parking brake before moving mower.
MOWER DECK CUT HEIGHT LIFT LEVER:
•Located to the right and front of the operator.
•Controls the cutting height.
•Twelve positions of adjustment
•Depress trigger and move lever forward to lower deck.
•Depress trigger and pull lever back to raise deck.
Note: Always use high position for transport.
20
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:
•Located on the control panel to the operator’s right.
•Protection of the electrical system is by (1) 15 amp
circuit breaker.
•If circuit breaker trips, push button to reset.
•If this condition repeats, consult dealer for inspection
and repair.
CHOKE AND THROTTLE CONTROL LEVERS:
•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.
21
OPERATION INSTRUCTIONS
The safe and successful operation of the KODIAK® ELS-60 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 complete knowledge of all controls and their functions.
NEVER dismount mower without applying parking brake or
During initial operation, “learning to drive”, set throttle at slow speed.
Sound judgement by the operator will prevent accidents.
stopping engine.
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 parking brake is on.
6. Be sure mower blade drive is off.
7. Know how to stop engine. (Turn key to off position).
22
OPERATION INSTRUCTIONS
CAUTION Failure to follow these instructions may
result in personal injury.
STARTING INSTRUCTIONS:
1. Parking brake must be on, control levers in outward position
and blade drive disengaged.
2. Position throttle to 1/2 speed setting. If engine is cold, position
choke lever to the “on” position.
NOTE: Engine may require partial choke setting to start
even if the engine has been operated for a period of time.
3. Insert ignition key and turn to “start” position. When engine
starts, release ignition key. Key will return to “run” position.
4. Return choke to “off” position, if applicable.
5. Move “throttle” to maximum speed position.
6. Release parking brake.
7. Swing levers inward.
8. 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: Engage blade drive with throttle in the mid-range
position. When mowing (blades engaged), set throttle control to the MAXIMUM or wide open setting to ensure adequate cooling of the engine and to maintain mower deck blade speed.
23
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.
PARKING BRAKE SWITCH TEST:
a) Swing control levers to outward position b) Disengage blade drive switch c) Put parking brake in OFF position d) Turn ignition switch to START
Engine should not turn over or attempt to start.
CONTROL LEVER SWITCH TEST:
a) Disengage blade drive switch b) Put parking brake in ON position c) Swing control levers inward d) 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.
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.
BLADE DRIVE SWITCH TEST:
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 SWITCH TEST:
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 slightly off seat.
ENGINE SHOULD STOP!
NOTE: If any safety check fails, do not operate the
mower until the system has been checked and repaired
by an Authorized Dixon® Dealer.
25
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 3/4” to 1” off the grass at any one time. Attempting to cut more grass will result in the deck plugging and cause the engine to stall.
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 up blade.
26
OPERATION INSTRUCTIONS
MOWING WITH A MULCHING ATTACHMENT
(continued):
7. Keep the underside of the mower deck clean.
Remove all grass and dirt build-up from the underside of the pan, the baffles and deflectors after each use.
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 evenlydisperse
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:
a. Raise the height-of-cut setting on your
mower.
Never, under any circumstances,
b. It may be necessary to cut your grass
more frequently.
c. Operate the mower at a slower ground
speed.
d. Overlap cutting swaths instead of cutting
a full swath with each pass.
e. Mow across the marginal areas a second
time.
f. CUT HIGH - MOW OFTEN!
27
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.
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.
28
Never, under
OPERATION INSTRUCTIONS
MOWING WITH A GRASS CATCHER
ATTACHMENT (continued):
7. Maintain sharp blades throughout the cutting
season.
“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.
Some grass catching attachments require a
WARNING
•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.
Failure to observe the following instructions may result in personal injury.
29
OPERATION INSTRUCTIONS
SIDE DISCHARGE OF THE CLIPPINGS:
In order to achieve optimum performance when side discharging the grass clippings, please read and follow the tips listed below. Additional information can be found in the Troubleshooting guide.
CAUTION To avoid personal injury, be sure that the
deflector is properly installed on the discharge chute.
1. Set engine speed control to the wide open or full setting.
2.
Do not attempt to cut grass when it is wet. Wet grass will clog the underside of the deck and discharge area.
3. If the grass is tall, place the mower deck cut height lever in the top or second notch. “Initially” overlap cutting swaths instead of a full swath with each pass. Some applications may require a second cutting.
4.
Keep the underside of the mower deck clean.
Frequent removal of dried grass and dirt will allow the clippings to discharge correctly.
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.
30
Never, under
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 cutting swaths instead of a full swath with each pass. Some applications may require a second cutting.
Keep the underside of the mower deck clean.
Maintain sharp blades throughout the cutting season.
As a rule of thumb, never cut off more than 1/3 of the total grass blade length. Correct mowing height can reduce weeds and disease by 50% to 80%.
The following grass cut heights are based on adequate moisture conditions and normal thatch build-up in a healthy lawn. Some locations and applications may require slightly different cut heights. If in doubt, consult your local lawn professional for assistance.
Grass Types
Best Cut Heights Bermudagrass 1 - 2” Bluegrass 2 - 3” Buffalograss 1
1/2
-3” Ryegrass 2 - 3” Tall Fescue 3-3
1/2
Zoysiagrass 1 - 3”
31
”
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 500 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 behind 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 bolt counter-clockwise two 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.
32
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.
Do not wear watch or jewelry.
Do not wear loose fitting clothes, and observe all
common safety practices with tools.
MAINTENANCE SCHEDULE
•Adjust traction drive idler........................................after 5 hours break-in
•Check deck serpentine belt.................................after 20 hours break-in
•Check crankcase oil level.............................................before each use
•Clean grass from hydrostat fans.....................................before each use
•Clean grass & debris from muffler & manifold area...........before each use
•Clean grass under deck..................................................after each use
•Check tire pressure........................................................every 10 hours
•Inspect blades for sharpness...........................................every 10 hours
•Check hydrostatic transmission fluid...............................every 25 hours
•Clean air filter element....................................................every 25 hours
•Check traction drive idler adjustment................................every 50 hours
•Grease all zerks............................................................every 50 hours
•Check all belts...............................................................every 50 hours
•Change engine crankcase oil & filter.....(5 hours break-in)every 50 hours
•Change engine oil filter...................................................every 50 hours
•Replace air filter element.............................
•Replace spark plugs.....................................................every 100 hours
•Change hydrostat oil & oil filter..........(100 hours break-in)every 500 hours
annually or every 100 hours
33
CARE AND MAINTENANCE
CUTTER BLADE MAINTENANCE:
CAUTION Stop engine and remove ignition key
for safety. Wear heavy, thick gloves when holding onto cutter blade, avoid the sharp edge of the blade.
Check sharpness of mower blades after every 10 hours of operation. Observe proper blade position prior to removal.
1. 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. Be sure blade is centered on pilot before tightening to 60 ft. lbs.
Blades should be discarded when worn excessively.
New Blade
When notch starts, discard blade
34
DANGEROUS!
DO NOT USE BLADE IN THIS CONDITION!
CARE AND MAINTENANCE
ENGINE:
For complete maintenance and operating information of the engine, please refer to the maintenance instructions furnished by the engine manufacturer included in your Zero Turn Radius mower information packet.
CAUTION
Battery contains sulfuric acid electrolyte which is poisonous and corrosive.
BATTERY:
This is a maintenance-free battery and the fluid level cannot be checked.
•Charge battery if required.
OFF SEASON BATTERY STORAGE:
•DO NOT remove battery from mower.
•Clean top of battery and terminals with baking soda and water.
•Identify each cable so they can be reconnected to the correct terminal.
•Disconnect cables from terminals. ALWAYS discon­nect ground cable first and reconnect last.
•Charge battery.
Note: Your Dixon® mower comes equipped with a quick
disconnect harness for the optional Dixon® Battery Manager. The Dixon® Battery Manager maintains the proper charge levels during periods of inactivity and may prevent premature battery failures. Contact your
dealer for more information.
35
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 13 x 5.00 - 6 16-21 lbs. Rear tires 20 x 12.0 - 10 8-14 lbs.
Lug nuts or lug bolts should be checked regularly for tightness.
LUBRICATION:
CHASSIS: (9) grease zerks
LOCATIONS: (2) each front wheel caster
(1) each mower deck hub (1) each brake arm
SERVICE INTERVALS: Every 50 hours of operation or
once per season.
RECOMMENDED Name brand wheel bearing GREASE: or multi-purpose grease
(3 pumps each)
36
CARE AND MAINTENANCE
BELTS:
Check belts every 50 hours. Replace any belts found to be in poor condition.
BELT TENSION:
Mower Deck Serpentine Belt: P/N 9758
Manual adjustment. Refer to illustrationfor adjustment procedure.
Engine to Mower Deck Belt: P/N 17179
The engine to mower deck drive belts are automatically held in proper tension by springs which push the deck assembly forward and do not require any additional adjustment to be made.
Idler Weldment
“L” Rod
Idler Shock Mount
(Serpentine)
Tighten or Loosen
Hex Nut to achieve
this dimension (approximate)
Hex Nut
3/4”
Note: Belt deflection or movement should be approximately
1/4” when measured at mid-point between pulleys. Periodically inspect both belt and idler systems.
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 side of the engine crankcase.
2. Place a suitable container under the drain valve hose.
3. To drain, turn hex head valve stem counter-clockwise with a 10mm wrench or socket. Open to full open (approximately 7 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 recommenda-
tions for frequency of oil changes.
Hex Head Valve
Stem
38
CARE AND MAINTENANCE
CAUTION
HOT oil may cause burns. Allow engine to cool before draining oil.
OIL FILL:
1. Clean any spilled oil from engine and chassis.
2. Refill engine with type, and quantity of oil
recommended by the engine manufacturer in engine literature.
NOTE: Engine oil changes on the KODIAK® ELS-60
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.
39
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-50 Synthetic 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-50 Synthetic Hydrostatic Fluid is specifically formulated to provide excellent all-climate performance and extended time between
FLUID FILTER: P/N 18045 - IMPORTANT
The fluid filter is a special design for use on “vacuum or suction” oil flow systems.
DO NOT: Use automotive engine oil filters. These
filters require a “pressure” to allow oil flow. Usage will result in an “air-lock” condition with possible damage.
40
oil changes.
CARE AND MAINTENANCE
HYDROSTAT FLUID MAINTENANCE
PROCEDURE:
Check the fluid level in hydrostatic transmisison fluid reservoir after every 25 hours of usage. Clean the fluid reservoir cap and the area around it prior to removal. Check the fluid level. Fluid should be approximately 1/4” below top of fluid tank baffle. Replenish as needed with
Dixon Blue™ 15W-50 Synthetic Hydrostatic
Fluid
. DO NOT OVERFILL. When checking the fluid
level, be very careful to keep the reservoir clean.
Change the fluid in the reservoir and hydrostatic transmission fluid filter after the first 100 hours of use, then every 500 hours after that. Remove the filter and be sure all fluid has drained from the reservoir. Replace with a new OEM filter (P/N 18045) and
15W-50 Synthetic Hydrostatic Fluid
Dixon Blue™
.
CAUTION: standard 20W-50 motor oil or similar synthetic motor oils.
DO NOT USE OR ADD STANDARD (RED) HYDRAULIC/ TRANSMISSION OIL IN YOUR DIXON HYDROSTATIC DRIVE. DAMAGE TO THE DRIVE COMPONENTS MAY OCCUR. USE ONLY APPROVED
15W-50 SYNTHETIC HYDROSTATIC FLUID
TYPE ENGINE OIL.
Dixon Blue™ is only compatible with
DIXON BLUE™
OR 20W-50
41
CARE AND MAINTENANCE
NEUTRAL ADJUSTMENT
1. Lift seat.
2. Block up the unit so that the drive wheels are off the ground.
3. Loosen ball joint jam nuts on control rod. Note: The front jam nuts are left hand threads.
4. With steering control arms in the “out” neutral position, start the engine and run at fast idle.
5. Adjust the neutral position by turning the control rod until the wheels do not rotate.
6. Re-tighten the jam nuts on the control rod and check to see that the drive wheels are not turning.
7. Repeat steps 3-6 for the other side.
8. Shut off engine before removing the blocks.
42
CARE AND MAINTENANCE
NEUTRAL SPRING ADJUSTMENT:
1. Loosen set screws on center spring stop collar located on the control rods. (Requires a 1/8” Allen wrench).
2. Swing control lever out. Tighten set screw on lock collar.
3. Repeat for opposite side.
4. Engage parking brake and lower seat frame. Release parking brake and swing control levers in. If wheel creeps, repeat steps 1 and 2.
5. Stop engine and remove rear of machine from jack or blocks.
6. Return the seat to the operating position.
7. Drive machine with both levers in top speed position. If one side now drives slightly faster than the other adjust forward speed bolt in to contact stop sooner.
43
CARE AND MAINTENANCE
MOWER DECK LEVELING PROCEDURE:
There are a total of (4) threaded adjusters which will control the attitude or pitch of the mower deck. The adjusters have locknuts on the bottom which can be turned up or down to raise or lower the front and rear of the mower deck. Deck should be level or pitched slightly higher in rear.
A. Place the mower on a smooth level surface with front
casters positioned t owards deck. Check tire pressures to insure the mower has a correct stance. Inflate tires as required:
Front 16 - 21 lbs maximum Rear: 8-14 lbs maximum
NOTE: To insure accuracy of leveling procedure, mower
deck drive belt must be installed prior to leveling deck.
B. Wear heavy gloves. Turn each outer blade tip to
align with the deck or in a side-to-side manner.
C. Measure from the floor surface up to the bottom of the
blade tip on the discharge side of the mower deck. Retain this measurement. Move to the opposite side, check that measurement is the same. If adjustment is required, turn the nut on the bottom of the front threaded adjuster up or down until both side-to-side measurements are equal. Retain measurement.
44
CARE AND MAINTENANCE
MOWER DECK LEVELING PROCEDURE
(continued):
D. Turn both outer blades to align with the deck in
front-to-rear manner. Turn left rear adjuster nut up or down until rear of mower deck is positioned level to 1/8” higher in the rear than the side-to-side measurement. At this time, the mower deck will be suspended on (3) points (both front adjusters and the left rear adjuster). Move the right rear adjuster and take out the slack which will be present by turning adjuster locknut up.
E. Confirm measurements once again. Blade tips
should be level in a side-to-side manner. In the rear, blade tips should be level to 1/8" higher than side-to-side measurement. In the front, blade tips should be level to 1/8" lower than side­to-side measurement.
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 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 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 16).
PARTS/SERVICE:
See your Dixon® dealer for replacement parts, warranty or service.
46
CARE AND MAINTENANCE
MOWER DECK REMOVAL:
1. Remove mower deck drive belt. To relieve belt
tension, insert 5101 link (at front of lift frame) into
tab illustrated below. Move lift handle into the lowest cut position. Belt can now be removed from mower deck pulley.
2. Remove front and rear deck hanger pins, as illustrated below.
3. Slide deck from beneath chassis.
4. Reverse procedure to re-install deck 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- - - - - - - - - - - - - - - - - - - - - - - - -reset breaker Dead battery- - - - - - - - - - - - - - - - - - - - - - - - - - charge or replace Solenoid- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer Ignition switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer Starter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
2. ENGINE WILL TURN OVER BUT WON’T START
No fuel- - - - - - - - - - - - - - - refuel and/or clean or replace fuel filters
3. HARD TO START ENGINE
Fuel line clogged- - - - - - - - - - - - - clean fuel line and check fuel filter Faulty fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
4. ENGINE STARTS BUT CUTS OUT
Water in fuel- - - - - - - - - - - - - - -drain old fuel-replace with new fuel Clogged fuel line- - - - - - - - - - - - - - - - - - - - - - - - - - check fuel filter Fuel tank vent plugged- - - - - - - - - - - - - - - - - - - - - -clean fuel vent Faulty fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
5. ENGINE OVERHEATED
Air intake screen or fins clogged- - - - - -clean intake screen and fins Oil level too low or too high- - - - - - - - - - - - - - - - - - - -adjust oil level Running engine too slow - - - - - - - - - - - - - - - - - -run engine faster
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- - - - - - - - - - - - - - - - - - - - - -consult dealer Transmission by-pass may be engaged- - - - disengage
7. MOWER LOSES POWER OR TRANSMISSION OVERHEATS
Engine air filter-- - - - - - - - - - - - - - - - - - - - - - - - - - clean or replace Transmission damage- - - - - - - - - - - - - - - - - - - - - - -consult dealer
8. ENGINE STALLS WHEN BLADES ARE ENGAGED
Operator not on seat- - - - - - - - - - - - - - - - - - - - - - - - - -sit on seat Faulty interlock system- - - - - - - - - - - - - - - - - - - - - - consult dealer Fauty blade spindle bearing - - - - - - - - - - - - - - - - - - consult dealer Deck drive belt not properly routed- - - - - - - - - - - - - - - - - - reroute Blades blocked by foreign material - - - - - - - - - - - clean under deck
(see page 32)
9. DRIVE SYSTEM
Mower pulls to side- - - - - - -check tire inflation/adjust control linkage Mower creeps in neutral- - - - - - - - - - - - - - - - adjust control linkage 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
49
STANDARD SERVICE PARTS LIST
Blades
*Hi-Lift Fuson - P/N 13921
Super Hi-Lift Fusion - P/N 13869
Hi-Lift - P/N 13953
Standard Lift Fusion - P/N 13997
Standard Lift - P/N 13996 Gator Fusion - P/N 13955
*Factory installed
Belts
Engine to Mower Deck - P/N 17179
Serpentine - P/N 9758
Engine to Hydros - P/N 10959
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.
50
OWNER’S INFORMATION
Date of Purchase
Mower Model Number
Mower Serial Number
Purchased From
Name
Address
DATE OIL CHANGED DATE ENGINE TUNED
Dixon Industries, Inc.~P.O. Box 1569~Coffeyville, Ks~620-251-2000~Fax 620-251-4117
Dixon® and ZTR® are registered trademarks of
Dixon Industries, Inc.
WARNING:
DIXON INDUSTRIES, INC. P.O. Box 1569 Coffeyville, Ks 67337-0945 620-251-2000
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
KODIAK® ELS-60
Part No. 11806-106
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