Dixon 18124-0804 Lawn Mower User Manual
Contents
1. 57 KODIAK Safety Instructions amp Operator s Manual Model Year 2005 IMPORTANT READ CAREFULLY The Dixon ZTR mower is both easy and fun to operate However any power mower must be operated properly to be safe It is not a toy or a recreational vehicle Before you start to use the mower read this Operator s Manual carefully It contains valuable information that is necessary for the safe operation of the machine Observe all safety rules and become completely familiar with the controls The information contained in this manual applies to all Dixon Kodiak ZTR mowers See your authorized Dixon dealer for warranty service parts and repairs or to answer any questions you may have about your new Dixon amp ZTR TABLE OF CONTENTS Page SAFETY amp 4 15 WARRANTY 16 17 SPECIFICATIONS iciatis 18 19 SEATADJUSTMENT ERE 20 CONTROLS etus scenic 21 24 OPERATION INSTRUCTIONS 25 35 CARE amp MAINTENANCE 36 48 STANDARD SERVICE PARTS LIST 49 50 TROUBLESHOOTING 111011111 11 51 52 KODIAK Part Number 18124 0804 SAFETY A 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 v oy NS Bla2. 1 4 when measured at mid point between pulleys Periodically inspect both belt and idler systems 37 A CARE AND MAINTENANCE CAUTION HOT oil may cause burns Allow engine to cool before draining oil CHANGING THE ENGINE OIL 1 5 6 NOTE Hex Head Valve d Stem The Dapco oil drain valve is located on either side of the engine crankcase depending on the type of engine installed on your ZTR Placea suitable container under the drain valve hose Todrain turn hex head valve stem counter clockwise with a 10mm wrench or socket Open to full open approximately 7 turns After engine is drained tighten hex stem Change oil filter Fill with oil see steps on next page Refer to engine manufacturer s recommenda tions for frequency of oil changes 38 CARE AND MAINTENANCE HOT oil may cause burns Allow A CAUTION 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 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 Theuse of any other oil ftiler may cause damag
3. Push do not ride the mower when loading and unloading WARNING A Failure to observe the following safety instructions could result in serious injury or death GENERAL OPERATION continued Protect your eyes Always wear safety goggles or safety glasses with side shields when operating mower Data indicates that operators age 60 years and above 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 and counterweights Maintain or replace safety amp 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 A 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
4. Ks 620 251 2000 Fax 620 251 4117 F HCCOME Dixon and ZTR are registered trademarks of Dixon Industries Inc The engine exhaust from this product contains A wonnine chemicals known to the State of California to cause cancer birth defects or other reproductive harm DIXON INDUSTRIES INC P O Box 1569 Coffeyville Ks 67337 0945 KODIAK 620 251 2000 Part No 18124 0804
5. 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 LEFT HYDRO PUMP wt Pe aD FREEWHEEL VALVE 32 CARE AND MAINTENANCE A WARNING Failure to observe the following instructions may result in personal injury Before performing any maintenance turn off engine allow to cool amp 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 after 5 hours break in eCheck deck serpentine
6. reservoir and hydrostat transmission oil filter after the first 100 hours of use Then every 500 hours after that Remove the filter and be sure all oil has drained from the reservoir Replace with a new OEM filter P N 18045 and SAE 20W 50 motor oil Please dispose of used oll at proper collection centers 41 CARE AND MAINTENANCE NEUTRAL ADJUSTMENT 1 Lift seat 2 Blockupthe unitso thatthe 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 Adjustthe 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 18 Loosen set screws center spring stop collar located on the control rods Requires a 1 8 Allen wrench Swing control lever out Tighten set screw on lock collar Repeat for opposite side Engage parking brake and lower seat frame Release parking brake and swing control levers in If wheel creeps repeat steps 1 and 2 Stop engine and remove rear of machine from jack or blocks Return the seat to the operating position Drive machine with both l
7. slopes The added weight may change the stability of the mower thus creating the potential for tip over WARNING A 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 WARNING A 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 negativ
8. tips listed below 1 Read and follow the installation instructions that are included with your grass catcher Set engine speed control to the wide open or full setting Do not attempt to cut grass when it is wet Wet grass will clog both the underside of the deck and the attachment chutes Empty bags often to prevent plugging 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 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 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
9. DRIVE SYSTEM ENGINE STARTING SYSTEM TIRES CAPACITIES DIMENSIONS SPECIFICATIONS KODIAK 11 rectangular tube Designed for operator comfort by use of high density closed cell foam padded back and arm rests upholstered with Cordura water repellent fabric Seat is adjustable fore and aft Mounted on operator suspension system Made of 11 GA fabricated welded construction with external reinforcement ribs Three blades combine for a 50 cut width Cut height approximately 1 5 to 5 via 8 position lift handle Electric clutch Each rear wheel is independently driven by a Parker 10cc pump and TEO230 wheel motor Each mower is powered with either a 19HP Kawasaki 2OHP Honda 2OHP Kohler or a 21 HP Briggs amp Stratton Vanguard twin cylinder engine overhead valve air cooled gasoline full pressure lubrication with oil filter Electric by key switch operation with safety interlocks on parking brake and blade drive clutch Front 13 x 5 x 6 smooth tread 16 21 Ibs Rear 20 X 10 X 10 Turf Master 8 14 Ibs Fuel 11 gallon approximately Hydrostat Oil tank 4 quart with in line 25 micron filter Engine 2 qts SAE 10W30 with filter Width 60 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 adjustme
10. NE 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 see page 32 7 MOWERLOSES POWER OR TRANSMISSION OVERHEATS Engine air filter clean or replace Transmission damage consult dealer 8 ENGINE STALLS WHEN BLADES ARE ENGAGED Operator not 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 fore
11. RIODS 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 not 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 All Dixon warranty must be accomplished by authorized Dixon dealers and in accordance with Dixon amp warranty po
12. belt after 20 hours break in eCheck crankcase oil before each use Clean grass from hydrostat 2 1 before each use Clean grass amp debris from muffler amp manifold area before each use Clean grass under after each use eCheck tire every 10 hours Inspect blades for every 10 hours eCheck hydrostatic transmission fluid every 25 hours Clean air filter every 25 hours eCheck traction drive idler adjustment every 50 hours Grease all every 50 hours Gheck all belts tee deer every 50 hours Change engine crankcase oil amp filter B hours break in every 50 hours Change engine oil filter every 50 hours Replace air filter element annually or every 100 hours Replace spark every 100 hours Change hydrostat oil amp oil filter 100 hours break in every 500 hours 33 CARE AND MAINTENANCE CUTTER BLADE MAINTENANCE A 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 C
13. 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 WARNING A 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 WARNING A 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
14. de S 2 Run Over Back Over SAFETY A 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 A 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 A CAUTION WARNING A 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 op
15. e 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 A 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
16. e to the engine PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS PROTECT YOUR ENVIRONMENT 39 CARE AND MAINTENANCE HYDROSTATIC TRANSMISSION OIL amp FILTER SERVICE Dirt or water in oil can ruin the hydrostatic transmissions SERVICE INTERVALS 1 Initial filter service 50 hours 2 Every 250 hours or once a year thereafter OIL REQUIREMENTS Any high quality engine oil with an API classification of SG CD is recommended RECOMMENDED OIL WEIGHT Normal operation temperatures 20W50 Cold climate usage 10W40 Another alternative that will provide excellent all climate performance and extended time between oil changes is a 15W50 synthetic engine oil OIL FILTER P N 18045 IMPORTANT The oil filter is a special design for use on vacuum or suction oil flow systems 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 OIL MAINTENANCE PROCEDURE Check the oil level in hydrostatic transmisison oil reservoir after every 25 hours of usage Clean the oil reservoir cap and the area around it prior to removal Check the oil level Oil should be approximately 1 4 below top of oil tank baffle Replenish as needed with SAE 20W 50 motor oil DO NOT OVERFILL When checking the oil level be very careful to keep the reser voir clean Change the oil in the
17. 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 amp 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 arule 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 ina 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 9 Buffalograss 112 3 Ryegrass 2 3 Tall Fescue 3 31 Zoysiagrass 1 3 31 OPERATION INSTRUCTIONS TOWING TRAILERS AND OTHER ATTACHMENTS
18. er per CONTROL instructions on Page 19 A 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 23 OPERATION INSTRUCTIONS TESTING OF SAFETY INTERLOCK SYSTEMS A 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 Swing control levers to outward position Disengage blade drive switch Put parking brake in OFF position Turn ignition switch to START b C d 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 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 A 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 bra
19. erate 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 A 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 atrailer ortruck
20. 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 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 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
21. evers 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 asmooth level surface with front casters positioned towards deck Check tire pressures to insure the mower has a correct stance Inflate tires as required Front 16 21 los maximum Rear 8 14 Ibs maximum NOTE Toinsureaccuracy ofleveling 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 measurementis the same If adjustmentis required turn the nut onthe bottom of the frontthreaded 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 Turnleft rear adjuste
22. 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 WARNING A 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 Grizzly amp SilverTip Mowers DIXON WARRANTS ITS ZTR MOWERS AGAINST DEFECTS IN MATERIAL AND WORKMANSHIP FOR THE PE
23. heck sharpness of mower blades after every 10 hours of operation Observe proper blade position prior to removal 1 2 Loosen blade bolt and remove When replacing blade tighten Safely raise front of mower Hold or block blade from turning PILOT blade blade bolt securely Refer to diagram Be sure blade is centered on pilot before tightening nut to 60 ft Ibs Blades should be discarded when worn excessively ui vo DO NOT USE BLADE IN THIS New Blade gt CONDITION When notch starts discard blade 34 DANGEROUS 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 A CAUTION 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 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 Batter
24. ign 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 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 13919 Super Hi Lift Fusion P N 13868 Hi Lift P N 13948 Standard Lift Fusion P N 13950 Standard Lift P N 13949 Gator P N 13952 Factory installed Belts Engine to Mower Deck P N 6111 Serpentine P N 1300 Engine to Hydros P N 18155 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 ITR on 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
25. 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 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 T CAUTION To avoid personal injury be sure that the deflector is properly installed on the discharge chute 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
26. ke 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 Ina 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
27. licy and allowances All warranty claims must be submitted to Dixon Industries for approval 4 Warranty labor reimbursement to dealers based on published Dixon flat rate schedule 5 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 6 Battery warranty is limited to 90 days from date of purchase 7 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 and tires 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 8 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 CHASSIS SEAT MOWER DECK BLADE DRIVE
28. n 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 func tions During initial operation learning to drive set throttle at slow speed Sound judgement by the operator will prevent accidents BEFORE OPERATING MOWER NOOO RO Read engine manufacturer s operating and maintenance instructions Read and observe all safety instructions on your mower and in the manual Check engine oil Check fuel cap to be sure it is in place Be sure parking brake is on Be sure mower blade drive is off Know how to stop engine Turn key to off position 22 OPERATION INSTRUCTIONS A CAUTION Failure to follow these instructions may result in personal injury STARTING INSTRUCTIONS l 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 8 if the engine has been operated for period of time Insert ignition key and turn to start position When engine starts release ignition key Key will return to run position Return choke to off position if applicable Move throttle to maximum speed position Release parking brake Swing levers inward Operate mow
29. nt position 2 Slide seat forward or backward 3 Release seat slide adjuster Seat Slide Adjuster 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 Du amea shy mar NEUTRAL SLOW FAST SLOW FORWARD FORWARD RIGHT REVERSE 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 A CAUTION Engage parking brake before starting engine TO SET PARKING BRAKE The hand operated parking brake is located on
30. r 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 Inthe front blade tips should be level to 1 8 lower than side to 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 Left Rear Adjuster Deck Leveling Adjustment Points 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 i
31. s located on frame at rear of engine WARRANTY Refer to warranty information pages 16 PARTS SERVICE See your Dixon dealer for replacement parts warranty or service 46 CARE AND MAINTENANCE MOWER DECK REMOVAL 1 Remove mower deck drive belt To relieve belt tension insert 5283 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 Insert end of link here lift frame 2 Remove front and rear deck hanger pins as illus trated 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 noton engage parking brake Circuit breaker trips reset breaker Dead battery charge or replace Solen id consult dealer Ignition switch denar diete consult dealer MIC E 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 ENGI
32. 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 Eight 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 elf 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 will depend upon the operator having the correct knowledge of all controls used o
33. y 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 13x5 00 6 16 21 lbs Rear tires 20x10 0 10 8 14 lbs Lug nuts or lug bolts should be checked regularly for tightness LUBRICATION CHASSIS 7 grease zerks LOCATIONS 1 each front wheel caster 1 each mower deck hub 1 each deck lift shaft 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 1300 Manual adjustment Refer to illustrationfor adjustment procedure Engine to Mower Deck Belt P N 6111 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 Idler Shock Mount 3 4 42 44 50 Serpentine Tighten or Loosen Hex Nut to achieve this dimension Note Beltdeflection or movement should be approximately
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