OPERATOR’S MANUAL 3000 SERIES ZTR® 2002
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 the operator’s manual carefully and become completely familiar with the controls. The information contained in this manual applies to all Dixon® ZTR® 3000 Series Mowers. Your Dixon dealer will gladly answer any questions. See your dealer for warranty service, parts and repairs.
INDEX Page Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-15 Seat Adjustment Instructions . . . . . . . . . . . . . . . . . . . . . . . . 16 Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-19 Operation Instructions. . . . . . . . . . . . . . . . . . . 20-29 Care & Maintenance. . . .
SAFETY RIDING LAWN MOWERS, IF IMPROPERLY OPERATED, CAN CAUSE SERIOUS INJURY OR DEATH. The most common causes of injury to the operator or bystander... BLADE CONTACT TIP OVER RUN OVER BACK OVER ...read and understand this manual to prevent injuries.
SAFETY Safety Alert Symbol When you see this symbol, BE ALERT to the potential for injury. Follow 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.
SAFETY Failure to observe the following safety instructions could result in serious injury or death. GENERAL OPERATION: •Read, understand, and follow all instructions in the 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.
SAFETY GENERAL OPERATION (continued): •Turn off blades when not mowing. •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. •Watch for traffic when operating near or crossingroadways. •Use extra care when loading or unloading the mower into a trailer or truck. Do not ride the mower when loading and unloading.
SAFETY 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 cannot back up the slope or if you feel uneasy on it, do not mow it! DO •Mow across the slope with your Dixon ZTR - never up or down. •Remove obstacles such as rocks, tree limbs, etc. •Watch for holes, ruts or bumps. Uneven terrain could overturn the mower. Tall grass can hide obstacles. •Use slow speed.
SAFETY 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.
SAFETY SERVICE: •Use extra care in handling gasoline and other fuels. They are flammable and vapors are explosive. Use only an approved container. Never remove fuel cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke while refueling. Never refuel the mower indoors. Never store the mower or fuel container inside a building where there is an open flame. If fuel is spilled on clothing, change clothing immediately.
SAFETY SERVICE (continued): •Never run a mower inside a closed area. The exhaust fumes are toxic. •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. •Keep mower free of grass, leaves, or other debris buildup. Clean up oil or fuel spillage. Allow mower to cool before storing. •Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting.
DIXON INDUSTRIES, INC. a BLOUNT company Airport Industrial Park P.O. Box 1569 Coffeyville, Ks 67337- 0945 620-251-2000 Fax 620-251-4117 DIXON LIMITED WARRANTY POLICY 3000 & 4000 Series WARRANTY: Home Owner Application: This Dixon Warranty term is for a period of two (2) years from date of purchase. Commercial Application: Dixon mowers used for commercial application are warranted for 30 days from the date of purchase.
SPECIFICATIONS Model ZTR 3303 CHASSIS: Twin 12 gauge side frames and 7 gauge transmission and engine base plate. BODY: All body parts made of rotational molded polyethylene. Front body contains access panel for battery service. Seat tilts forward to allow transmission service. MOWER DECK: 11 GA stamped steel construction. Single 30” cut blade.
SPECIFICATIONS Model ZTR 3304 CHASSIS: Twin 12 gauge side frames and 7 gauge transmission and engine base plate. BODY: All body parts are made of rotational molded polyethylene. Front body contains access panel for battery service. Seat tilts forward to allow transmission service. MOWER DECK: 11 GA stamped steel construction. Single 30" cut blade. Cut height approximately 1" to 4" via 7 position lift handle. BLADE DRIVE: Mechanical; hand lever engagement.
SPECIFICATIONS Model ZTR 3014 CHASSIS: Twin 12 gauge side frames and 7 gauge transmission and engine base plate. BODY: All body parts are made of rotational molded polyethylene. Front body contains access panel for battery service. Seat tilts forward to allow transmission service. MOWER DECKS: 36" Deck: 11 GA Laser Cut Fabricated - 36" Cut Width 42" Deck: 13 GA Stamped Steel Construction - 42" Cut Width Cut height approx. 1" to 4" via 7 position lift handle. BLADE DRIVE: Electric clutch.
SEAT ADJUSTMENT INSTRUCTIONS Models ZTR 3303 - 3304 - 3014 1. Raise and push seat assembly forward. 2. Loosen five nuts and slide seat forward or backward to desired position. 3. Re-tighten nuts. DO NOT operate mower without seat adjustments properly tightened. 4. Push seat assembly back to closed position.
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 both control levers forward. •To increase speed, move levers further forward. TO GO BACKWARD: •From neutral position, gently pull both 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.
CONTROLS The Dixon ZTR has a unique transaxle that requires only two drive levers to control braking, turning, speed and direction. On initial operation, set throttle speed on slow. Operate with mower blade in “OFF” position. To avoid “over-controlling” the mower, use a light touch on the drive levers. Slight movements using fingertip control is all that is necessary.
CONTROLS BLADE DRIVE: Models ZTR 3303 & 3304 •Located to left of the operator. •To engage the mower blade, turn lever on floor slowly to the “ON” position. •To disengage mower blade, turn lever to the “OFF” position. BLADE DRIVE: Model ZTR 3014 •Located on the control panel, operator’s right. •To engage mower blades, pull up on the switch. •To disengage blades, push down. CIRCUIT BREAKER: •Protection of the electrical system is by (1) 15 amp circuit breaker.
OPERATION INSTRUCTIONS The safe and successful operation of the 3000 Series Mower 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. During initial operation, “learning to drive”, set throttle at slow speed. Sound judgement by the operator will prevent accidents.
OPERATION INSTRUCTIONS BEFORE OPERATING MOWER: 1. Read and observe all safety instructions on your mower and in the manual. 2. Read engine manufacturer’s operating and maintenance instructions. 3. Check engine oil. 4. Check fuel cap to be sure it is in place. 5. Be sure parking brake is on. 6. Mower blade drive is off. 7. Know how to stop engine. (Turn key to off position).
OPERATION INSTRUCTIONS STARTING INSTRUCTIONS: 1. Parking brake must be on, and blade drive disengaged. 2. Move throttle control to “choke” position if engine is cold, full throttle if warm. 3. Insert ignition key and turn to “start” position. When engine starts, release ignition key. Key will return to “run” position. 4. Move throttle from “choke” to desired speed position. 5. Release parking brake. 6. Operate the mower per the “CONTROL” instructions on Page 17.
OPERATION INSTRUCTIONS TESTING OF SAFETY INTERLOCK SYSTEMS: Do not operate mower if safety switches are not operating properly. PARKING BRAKE SWITCH TEST: a) Place parking brake in OFF position. b) Turn ignition switch to START. ENGINE SHOULD NOT TURN OVER OR ATTEMPT TO START! BLADE DRIVE SWITCH TEST: a) Place parking brake in ON position. b) Engage blade drive switch. c) Turn ignition switch to START.
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 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.
OPERATION INSTRUCTIONS GRASS HEIGHT AND CUTTING SUGGESTIONS: Do not attempt to cut grass when it is wet. If the grass is tall, place the mower deck cut height lever in the top or second notch. “Initially” overlap cutting swaths instead of a full swath with each pass. Some applications may require a second cutting. Keep the underside of the mower deck clean. Maintain sharp blades throughout the cutting season. As a rule of thumb, never cut off more than 1/3 of the total grass blade length.
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 of the recycled or mulched clippings. In order to achieve the best results, please read and follow the mulching tips listed below: 26 1. Set the engine speed control to the wide open or full setting. 2.
OPERATION INSTRUCTIONS MOWING WITH A MULCHING ATTACHMENT (continued): 6. 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. 7. 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: 1. Raise the height-of-cut setting on your mower.
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. 28 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 both the underside of the deck and the attachment chutes. Empty bags often to prevent plugging. 3.
OPERATION INSTRUCTIONS MOWING WITH A GRASS CATCHER ATTACHMENT (continued): 7. Operate the mower at a slower ground speed than when mowing without a grass catching attachment. 8. Some mowing applications/use of grass catchers may require that an optional weight box 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.
CARE AND MAINTENANCE CAUTION Bef ore perf or ming an Before perfor orming anyy maintenance maintenance,, tur turn engine,, n off engine allow to cool & remo ve key . remove key. Use extreme care when working on machiner machineryy. Do not wear wa tch or jewelr itting clothes watch jewelryy. Do not wear loose ffitting clothes,, and obser ve all common safety practices with tools observe tools.. MAINTENANCE SCHEDULE •Check deck serpentine belt...........................................
CARE AND MAINTENANCE ENGINE: For complete maintenance and operating information of the engine, please refer to the maintenance instructions furnished by the engine manufacturer and included in your Zero Turn Radius mower information packet. BATTERY: CAUTION Battery contains sulfuric acid electrolyte which is poisonous and corrosive. •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.
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 nut and remove blade. 4. When replacing blade, tighten blade nut securely. Refer to diagram.
CARE AND MAINTENANCE BELTS: Check belts every 50 hours. Replace any belts found to be in poor condition. BELT TENSION: Model ZTR 3303 & 3304: Manual Clutch - No adjustment. Model ZTR 3014 - 42” Deck: Belt tension maintained via spring loaded idler pulley Model ZTR 3014 - 36” Deck: Electric Clutch - Adjust idler shock mount per diagram.
CARE AND MAINTENANCE Deck Removal - Manual Clutch - Models 3303 & 3304 34 1. Place cut height lever in lowest cut position. 2. Loosen belt keepers. 3. Remove deck drive belt from engine pulley. 4. Using a slight upward twisting motion, remove link from engagement handle. 5, Turn handle fully to the left until handle clears stop on mower deck pan. Lift and remove handle through hole in lower body. 6. Remove hair pin cotter and washer from one end of deck support cross shaft.
CARE AND MAINTENANCE Deck Removal - Electric Clutch - Model 3014 1. Place cut height lever in lowest cut position. 2. For 36” decks, loosen nut on belt idler shock mount until belt can be removed from electric clutch pulley on the bottom of the engine. Refer to illustration below. For 42” decks, pull belt idler back to allow belt to be removed from idler pulley and electric clutch pulley. 3. Remove hair pin cotter and washer from one end of deck support cross shaft.
CARE AND MAINTENANCE FUEL SHUT OFF VALVE: The fuel shut off valve is located at the bottom rear of the fuel tank. Always turn the valve to the “OFF” position when the mower is stored or not in use. LUBRICATION: CHASSIS (number of grease zerks used): (5) for 30” (6) for 36” (7) for 42” LOCATIONS: (1) each front wheel caster &front wheel hub (1) each mower deck hub SERVICE INTERVALS: Every 50 hours of operation RECOMMENDED GREASE: Name brand wheel bearing or multipurpose grease.
CARE AND MAINTENANCE CAUTION HOT oil may cause burns. Allow engine to cool before draining oil. CHANGING THE ENGINE OIL: 1. The “Dapco” oil drain valve is located on the left side of the engine crankcase. 2. Place a suitable container under the drain valve. The fitting of a short piece of hose will help direct the oil. 3. To drain, turn hex head valve stem counter-clockwise with 10mm wrench or socket. Open to full open (approximately 7 turns). 4. After engine is drained, tighten hex stem.
CARE AND MAINTENANCE DRIVE SYSTEM ADJUSTMENTS: Due to both the complex nature of the transmission and the number of special tools required for service, adjustments should be entrusted to your dealer. There are a number of simple owner service items which greatly influence the performance of the drive system. 1. Front and rear tires must be inflated to proper specifications. 2. Rear drive chain tension. 3, Tighteness of all controls and linkages pertaining to the drive levers. 4.
CARE AND MAINTENANCE ELECTRICAL SYSTEMS: Keep all connections clean and tight. CLEANING THE MOWER: Wash mower periodically. Clean above and below deck. Note: Allow mower to cool before washing. If bearings are hot, they will draw moisture inside as they dry and cause corrosion. MOWER DECK PLATES: Check periodically. Replace bolted-on wear plates before shaft wears into mower deck plates. See illustration. SERIAL NUMBERS: The serial number is located on frame at rear of engine.
TROUBLESHOOTING 1.
TROUBLESHOOTING 6. ENGINE RUNS BUT MOWER WON’T MOVE FORWARD Drive belt broken or slipping- - - - - - - - - - - - - - - - - - - - replace drive belt Bad transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer 7. MOWER LOSES POWER OR TRANSMISSION OVERHEATS Engine air filter-- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -clean or replace Transmission damage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer 8.
STANDARD SERVICE PARTS LIST MODEL ZTR 3303 & 3304: Blades: Standard - P/N 2483 Hi-Lift - P/N 2484 Belts: Engine to Mower Deck - P/N 7725 Engine to Transmission - P/N 7650 MODEL ZTR 3014 (36” Deck): Blades: Standard - P/N 1324(Lo Lift) Hi-Lift - P/N 1351(R) Hi-Lift - P/N 1352(L) Belts: Engine to Mower Deck - P/N 7835 Engine to Transmission - P/N 7650 MODEL ZTR 3014 (42” Deck): Blades: Standard - P/N 8688 (Hi-Lift) P/N 6236 (Lo-Lift) Belts: Engine to Mower Deck - P/N 7725 Engine to Transmission - P
OWNER INFORMATION DIXON INDUSTRIES, INC. a BLOUNT International Inc. Co. P.O.
ZTR®Mowers WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Dixon® and ZTR® are registered trademarks of Dixon Industries, Inc. DIXON INDUSTRIES, INC. a BLOUNT International Inc. Co. P.O. Box 1569 Coffeyville, Ks 67337-0945 620-251-2000 3000 Series 3303-3304-3014 Part No.
