OPERATORS MANUAL ZTR CLASSIC ZTR® 2003
IMPORTANT - READ CAREFULLY The Dixon® ZTR® Classic 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 operators manual carefully and become completely familiar with the controls. The information contained in this manual applies to all Dixon® ZTR® Classic 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 Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . . . . . . . .14 Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-17 Operation Instructions. . . . . . . . . . . . . . . . . . . 18-27 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 & 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 crossing roadways. 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. DO If you cannot back up the slope or if you feel uneasy on it, do not mow it! 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 PROTECTION PLUS TWO YEAR LIMITED WARRANTY TRANSAXLE MODELS WARRANTY: Home Owner Application: Dixon Transaxle Models, used only at owners primary place of residence are warranted for a period of two (2) years from date of purchase. Commercial Application: defined as use other than, or in addition to, mowing at owners primary place of residence. Dixon Transaxle Models, used in commercial application are warranted for a period of (30) days from the date of purchase.
SPECIFICATIONS ZTR Classic CHASSIS: 11 GA welded rectangular tubing BODY: All body parts made of high density polyethylene. Dent and corrosion resistant. Front body contains access panel for battery service. MOWER DECK: 13 GA stamped steel construction. Three blades combine for a 42 cut width. Cut height approximately 1- 4 via 7-position lift handle. BLADE DRIVE: Electric clutch. TRANSMISSION: Each rear wheel is independently driven by chain and sprockets through a mechanical friction drive.
SEAT ADJUSTMENT INSTRUCTIONS Model ZTR Classic 14 1. Raise and push seat assembly forward. 2. Loosen seat adjustment knobs 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 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 CONTROL LEVERS 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. •To turn right, move right lever rearward of the left lever.
CONTROLS BLADE DRIVE: •Located on the control panel, on the operators right. •To engage the mower blades, pull up on the switch. •To disengage mower blade, push down. CIRCUIT BREAKER: •Protection of the electrical system is by (1) 15 amp circuit breaker. •If circuit breaker trips, push button to reset. •If this condition repeats, consult dealer for inspection and repair. THROTTLE CONTROL LEVER: •Located on control panel to operators right. •Throttle control for engine speed.
OPERATION INSTRUCTIONS The safe and successful operation of the ZTR Classic mower will depend upon the operator having the correct knowledge of all the 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 manufacturers 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 TESTING OF SAFETY INTERLOCK SYSTEMS: Do not operate mower if safety switches are not operating properly. BLADE DRIVE SWITCH TEST: a) Engage blade drive switch. b) 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) Engage blade drive switch. c) Raise slightly off seat.
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 16.
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 22 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.
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: 24 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. 26 1. Set engine speed control to the wide open or full setting and engage mower before entering area to be cut. 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 Before perfor orming anyy maintenance maintenance,, tur turn engine,, Bef ore perf or ming an n off engine allow to cool & remo ve key . remove key. machineryy. Use extreme care when working on machiner watch jewelryy. Do not wear loose ffitting clothes,, Do not wear wa tch or jewelr itting clothes observe tools.. and obser ve all common safety practices with 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: Transaxle Drive Belt: P/N 1684 Engine to Mower Deck Belt: P/N 6111 No adjustment required. No adjustment required. Correct belt tension is maintained through a fixed engine location and a spring loaded idler system. A pulsing movement of the belt idler will be observed both during engagement of the electric blade clutch and actual operation of the mower deck.
CARE AND MAINTENANCE MOWER DECK LEVELING PRCEDURE: 1. 2. 3. 4. 5. Place mower on a smooth, level surface and check tire pressures to insure correct stance. Tires should be inflated as follows: Front: 16-21 lbs Rear: 8-14 lbs Turn each outer blade tip to align with the deck in a side to side manner. Measure from the floor surface up to the bottom of the blade tip on the discharge side of the mower.Retain this measurement. Move to the opposite side and check to see if that measurement is the same.
CARE AND MAINTENANCE DECK REMOVAL: 1. Place cut height lever in lowest cut position. 2. 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. Slide shaft from chassis and mower deck. 4. Remove hair pin cotter and washer from each deck L-rod. Remove L-rods from lift arms. At this point, deck will drop down. 5. Carefully raise and support front of chassis.
CARE AND MAINTENANCE CAUTION HOT oil may cause burns. Allow engine to cool before draining oil. CHANGING THE ENGINE OIL: 1. The Dapco oil drain valve is located on the left side of the engine crankcase. 2. Place a suitable container under the drain valve hose. 3. To drain, turn hex head valve stem counter-clockwise with 10mm wrench or socket. Open to full open (approximately 7 turns). 4. After engine is drained, tighten hex stem. 5. Change the oil filter. 6. Fill with oil (see steps below).
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, Tightness of all controls and linkages pertaining to the drive levers. 4.
CARE AND MAINTENANCE REAR CHAIN ADJUSTMENT: To adjust the rear drive chains on the ZTR Classic, tighten the nut on top of the spring on each side of the mower chassis. Tighten until the chains have approximately 1/4 movement up and down when measured at a mid point. Refer to illustration. NOTE: Adjust rear drive chains after first 10 hours of operation and every 40 hours thereafter.
CARE AND MAINTENANCE LUBRICATION: CHASSIS: (5) grease zerks used LOCATIONS: (1) each front wheel caster (1) each mower deck hub SERVICE INTERVALS: Every 50 hours of operation RECOMMENDED GREASE: Name brand wheel bearing or multi-purpose grease. Once per season or 50 hours of operation (3 pumps each) Note: Lubrication of the mower deck hubs will help dispel moisture within the hub casting. Bearings are of a sealed variety. PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS.
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.
STANDARD SERVICE PARTS LIST Blades: P/N 8688 (Standard/Hi-Lift) P/N 6236 (Lo-Lift) Belts: Engine to Mower Deck - P/N 6111 Engine to Transmission - P/N 1684 Serpentine Blade Drive - P/N 1684 BRIGGS & STRATTON AIR AND OIL FILTER PART NUMBERS: Refer to engine manufacturers manual for correct service intervals for engine oil changes and air filter maintenance. Protect your engine investment, use only original equipment filters.
TROUBLESHOOTING 1.
TROUBLESHOOTING 6. ENGINE RUNS BUT MOWER WONT 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.
NOTES 42
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 44 ZTR Classic Part No.
