KODIAK® ZTR®
Operator’s manual
KODIAK 52, 21 KAW/968999576,
KODIAK 52, HONDA/968999577,
KODIAK 52, 20 KOH/968999578,
KODIAK 52, 25 KOH/968999579,
KODIAK 60, 25 KOH/968999580,
KODIAK 60, 25 B&S/968999581
Please read the operator’s manual carefully
and make sure you understand the
instructions before using the unit.
English
TABLE OF CONTENTS
Page
SAFETY & WARNING....................................4-15
WARRANTY........................................................16
SPECIFICATIONS.............................................17
SEATADJUSTMENT.........................................18
CONTROLS..................................................19-21
OPERATION INSTRUCTIONS....................22-32
CARE & MAINTENANCE............................33-45
TROUBLESHOOTING..................................46-47
STANDARD SERVICE PARTS LIST...............48
KODIAK®
Part Number 114518Rir - 11/07/06
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
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
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 and while
backing.
6
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 should you place hands or feet
under the mower deck or in the chute while blades or
impeller are still running.
To avoid personal injury from accidental clutch engage-
ment, 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 road-
ways.
Use extra care when loading or unloading the mower into
a trailer or truck. Push, do not ride the mower when
loading and unloading.
7
WARNING
Failure to observe the following safety instructions
could result in serious injury or death.
GENERAL OPERATION (continued):
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 mower-
related 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, dealer-
installed 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 embank-
ments. 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
Black BearTM, Kodiak®, MountainKodiak®, Kodiak® Diesel, Grizzly™&SilverTip™Mowers
DIXON® WARRANTS ITS ZTR® MOWERS AGAINST DEFECTS IN MATERIAL AND WORKMANSHIP
FOR THE PERIODS SET FORTH BELOW. THE SOLE REMEDY UNDER THIS WARRANTY IS
REPLACEMENT OR REPAIR OF PARTS INCLUDING LABOR COSTS.
THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS AND LIMITATIONS:
1. COMMERCIAL WARRANTY (use other than, or in addition to, mowing at owner’s primary place of
residence):
a. First two years - 100% parts and labor subject to the conditions and limitations described herein
with the exception of non-covered items specified below.
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 Industries, Inc. are warranted for one year
parts and labor in commercial use applications.
d. Pro Series Models are not subject to hour meter restrictions.
e. Warranty applies to new and unused mowers and is transferable.
2. RESIDENTIAL WARRANTY (used only at owner’s primary place of residence):
a. Three years - 100% parts and labor subject to the conditions and limitations described herein for
a period of three 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 is transferable.
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.
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 date of manufacture.
8. 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.
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.
16
SPECIFICATIONS
KODIAK®
CHASSIS:
SEAT:
11 GA - rectangular tube
Designed for operator comfort by use of high-density
closed cell foam padded back and arm rests, upholstered
with CorduraTM water-repellent fabric. Seat is adjustable
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 52” or 60”
cut width. Cut height approximately 1.5” to 5” via 12
position lift handle.
BLADE DRIVE:
DRIVE SYSTEM:
Electric clutch
Each rear wheel is independently driven by a Parker 10cc
pump and TJ0230 wheel motor.
ENGINE:
Each mower is powered with either a 21HP Kawasaki,
20 HP Honda, 20 HP or 25 HP Kohler, 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.
TIRES:
Front 13 x 5 x 6 smooth tread (15 lbs)
Rear 23 X 9.5 - 12 (15 lbs)(52” decks) or
23 X 10.5 - 12 (15 lbs)(60” decks)
CAPACITIES:
DIMENSIONS:
(approximate)
Fuel - 11 gallon (approximately)
Hydrostat Oil tank - 4 quart with in-line 25 micron filter
Engine - 2 qts. SAE 10W30 (with filter)
Width
48” outside rear wheel measurement (52”
decks)
52” outside rear wheel measurement (60”
decks)
Height
Length
Weight
70.5” ROPS up, 57” ROPS down
79” (52” decks), 81” (60” decks)
960 lbs. (52” decks)
990 lbs. (60” decks)
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 for-
ward.
•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.
Engage parking brake
CAUTION
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.
•Fifteen 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.
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™
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 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 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.
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. 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 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.
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. 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.
28
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.
Failure to observe the following instructions
may result in personal injury.
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.
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. 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.
30
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
Bermudagrass
Bluegrass
Buffalograss
Ryegrass
Best Cut Heights
1 - 2”
2 - 3”
11/2 -3”
2 - 3”
3-31/2”
Tall Fescue
Zoysiagrass
1 - 3”
31
OPERATION INSTRUCTIONS
TOWING TRAILERS AND OTHER ATTACHMENTS:
Towing a trailer or other attachment is not recommended.
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 belt.................................................after 20 hours break-in
•Check crankcase oil level.............................................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.............................annually or every 100 hours
•Replace spark plugs.....................................................every 100 hours
•Change hydrostat oil & oil filter..........(100 hours break-in)every 500 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.
DANGEROUS!
DO NOT USE
BLADE IN THIS
CONDITION!
New Blade
When notch starts,
discard blade
34
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.
Battery contains sulfuric acid electrolyte which
is poisonous and corrosive.
CAUTION
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 discon-
nect 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
Rear tires
15 lbs.
15 lbs.
Lug nuts or lug bolts should be checked regularly for tightness.
LUBRICATION:
CHASSIS:
(11) grease zerks
LOCATIONS:
deck lift (1)
pump idler arm (1)
front wheel casters (4)
mower deck hubs (3)
drive controls (2)
SERVICE INTERVALS:
Every 50 hours of operation or
once per season.
RECOMMENDED
GREASE:
Name brand wheel bearing
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.
37
CARE AND MAINTENANCE
HOT oil may cause burns. Allow
engine to cool before draining oil.
CAUTION
CHANGING THE ENGINE OIL:
1. The oil drain valve is located on either side of the
engine crankcase (depending on the type of engine
installed on your ZTR®).
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
HOT oil may cause burns. Allow
engine to cool before draining oil.
CAUTION
OIL FILL:
1. Clean any spilled oil from engine and chassis.
2. Refill engine with type, and quantity of oil recom-
mended by the engine manufacturer in engine
literature.
NOTE: Engine oil changes on the KODIAK™ 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 filter 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 -
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.
FLUID FILTER: P/N 539 102606 - 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
CARE AND MAINTENANCE
HYDROSTAT FLUID MAINTENANCE
PROCEDURE:
Check the fluid level in hydrostatic transmission 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 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 539 102606) and 15W-50
Synthetic Hydrostatic Fluid.
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 OR 20W-50 TYPE ENGINE OIL.
41
CARE AND MAINTENANCE
NEUTRAL ADJUSTMENT
1. Lift seat.
2. Blockuptheunitsothatthedrivewheelsareoff the
ground.
3. Loosen ball joint jam nuts on control rod.
Note: Thefront jamnutsarelefthandthreads.
4. With steering control arms in the “out” neutral
position, start the engine and run at fast idle.
5. Adjusttheneutralpositionbyturningthecontrolrod
untilthewheelsdonotrotate.
6. Re-tighten the jam nuts on the control rod and
checktoseethatthedrivewheelsarenotturning.
7. Repeat steps 3-6 for the other side.
8. Shut off engine before removing the blocks.
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.
PARTS/SERVICE:
See your Dixon® dealer for replacement parts, warranty
or service.
43
CARE AND MAINTENANCE
MOWER DECK LEVELING PROCEDURE:
Before performing any service or adjustment check list:
1. Engage parking brake.
2. Place blade-switch in the disengaged position.
3. Turn ignition switch to “OFF” position and remove
key.
4. Make sure blades and all moving parts have com-
pletely stopped.
5. Disconnect spark plug wire from all spark plugs and
place wire where it cannot come in contact with plug.
Blades are sharp. Protect your hands with
gloves and/or wrap blades with a heavy cloth
when handling.
1. Position the mower on a level, hard surface
2. Check the pressure in all four tires. See “Technical Data”
section in this manual.
3. Set deck cutting height at 4".
4. Rotate blades to align front to back.
5. Measure front blade tip, should be 4” from ground, if not
turn locknut on top of front eyebolt till measurement is
achieved. Check blade tip at front on opposite front blade.
Adjust locknut on front eyebolt as necessary.
44
CARE AND MAINTENANCE
MOWER DECK LEVELING PROCEDURE
(continued):
6. Check rear blade measurement, should be 4 1/4” from
ground, if not turn locknut on top of rear eyelbolt to
achieve measurement. Repeat procedure on opposite
side.
8. If deck leveling cannot be achieved call Technical
Support at toll free number 1-877-288-6673.
3
2
1
4
1. Front eyebolt
2. Front locknut
3. Rear locknut
4. Rear eyebolt
Leveling mower deck
45
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
46
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- - - - - - - - - - - - -disengaged
7. MOWER LOSES POWER ORTRANSMISSION 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
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/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
47
STANDARD SERVICE PARTS LIST
52"
Blades
*Hi-Lift - P/N 539 117911
*Factory installed
Belts
Engine to Mower Deck - P/N 539 114557
Engine to Hydros - P/N 539 106887
60"
Blades
*Hi-Lift - P/N 539 119840
*Factory installed
Belts
Engine to Mower Deck - P/N 539 114508
Engine to Hydros - P/N 539 106887
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.
48
OWNER’S INFORMATION
Date of Purchase
Mower Model Number
Mower Serial Number
Purchased From
Name
Address
DATE OIL CHANGED
DATE ENGINE TUNED
Dixon~401 N. Commerce St. Beatrice, NE 68310
Dixon® and ZTR® are registered trademarks of Dixon
The engine exhaust from this product contains
WARNING: chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm.
DIXON
401 N. Commerce St..
Beatrice, NE 68310
KODIAK®
Part No. 114518Rir - 11/07/06
|