BLACK BEAR™ ZTR® Safety Instructions & 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.
TABLE OF CONTENTS Page SAFETY & WARNING....................................4-15 WARRANTY........................................................16 SPECIFICATIONS.............................................17 SEAT ADJUSTMENT........................................18 CONTROLS..................................................19-22 OPERATION INSTRUCTIONS....................23-33 CARE & MAINTENANCE...........................34-47 TROUBLESHOOTING.................................
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.
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.
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.
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.
WARNING 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.
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.
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.
WARNING Failure to observe the following safety instructions could result in serious injury or death. SLOPE OPERATION (continued): DO NOT Do not turn on slopes unless necessary, and then, turn slowly and gradually downhill, if possible. Rapid uphill turns may cause tip-over. Do not mow near drop-offs, ditches, or embankments. The mower could suddenly turn over if a wheel is over the edge of a cliff or ditch or if an edge caves in. Do not mow on wet grass. Reduced traction could cause sliding.
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.
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.
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.
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.
DIXON® ZTR® PRO SERIES COMMERCIAL/RESIDENTIAL WARRANTY POLICY Black Bear™, Kodiak™, 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.
SPECIFICATIONS BLACK BEAR™ CHASSIS: 11 GA - rectangular tube SEAT: Designed for operator comfort by use of high-density closed cell foam padded back and arm rests, upholstered with CorduraTM water-repellent fabric. Seat is adjustable fore and aft. MOWER DECK: Made of 7 GA fabricated welded construction with external reinforcement ribs. Two blades combine for a 34” cut width. Cut height approximately 1.5” to 5.5” via 17 position lift handle.
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.
CONTROLS CONTROL LEVERS Note: For access to the seat, move control levers to neutral position and swing them outward. TO GO FORWARD •From neutral position, gently push control levers forward. •To increase speed, move levers further forward. TO GO BACKWARDS •From neutral position, gently pull control levers toward you. TURNING •Turning is controlled by moving one control lever slightly forward or rearward of the other. •To turn left, move left lever rearward of the right lever.
CONTROLS PARKING BRAKE: The parking brake is designed to hold the mower from moving and is not intended for use in stopping the mower while it is in motion. The engine will stop if the parking brake is engaged while the control levers are in the drive position. CAUTION Engage parking brake before starting engine. TO SET PARKING BRAKE: The hand operated parking brake is located on the left hand side of the mower. •To engage brake, pull lever up (to the rear). •To release brake, move lever forward (down).
CONTROLS MOWER DECK CUT HEIGHT LIFT LEVER: •Located to the right and front of the operator. •Controls the cutting height. •17 positions of adjustment •Depress trigger and move lever forward to lower deck. •Pull lever back to raise deck. •Set desired cut height with pin. •Use foot pedal to assist with raising and lowering deck. Note: Always use high position for transport. The two holes at the front of the quadrant are for 1-1/2” and 1-3/4” cut heights.
CONTROLS BLADE DRIVE: •Located on the control panel, on operator’s right. •To engage the mower blade, pull up on the switch. •To disengage mower blade, push down. CIRCUIT BREAKER: •Located on the control panel to the operator’s right. •Protection of the electrical system is by (1) 15 amp circuit breaker. •If circuit breaker trips, push button to reset. •If this condition repeats, consult dealer for inspection and repair. CHOKE AND THROTTLE CONTROL LEVER: •Located on control panel to operator’s right.
OPERATION INSTRUCTIONS The safe and successful operation of the BLACK BEAR™ 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. BEFORE OPERATING MOWER: 1.
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 desired speed setting. If engine is cold, position throttle lever in the “choke” 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.
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.
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.
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.
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.
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.
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. Use of grass catchers requires 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.
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.
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.
OPERATION INSTRUCTIONS TOWING TRAILERS AND OTHER ATTACHMENTS: Towing a trailer or other attachment that is too heavy could damage the drive or cause the mower to become unstable. Limit loads to 250 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.
CARE AND MAINTENANCE WARNING Failure to observe the following instructions may result in personal injury. Before performing any maintenance, turn off engine, allow to cool & remove key. Use extreme care when working on machinery. Do not wear watch or jewelry. Do not wear loose fitting clothes, and observe all common safety practices with tools. MAINTENANCE SCHEDULE •Adjust traction drive idler........................................after 5 hours break-in •Check deck serpentine belt........................
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.
CARE AND MAINTENANCE ENGINE: For complete maintenance and operating information of the engine, please refer to the maintenance instructions furnished by the engine manufacturer included in your Zero Turn Radius mower information packet. CAUTION Battery contains sulfuric acid electrolyte which is poisonous and corrosive. BATTERY: This is a maintenance-free battery and the fluid level cannot be checked. •Charge battery if required. OFF SEASON BATTERY STORAGE: •DO NOT remove battery from mower.
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 13 x 5.00 - 6 16-21 lbs. 23 x 8.5 - 12 8-14 lbs. Lug nuts or lug bolts should be checked regularly for tightness.
CARE AND MAINTENANCE BELTS: Check belts every 50 hours. Replace any belts found to be in poor condition. BELT TENSION: Engine to Mower Deck Belt: P/N 10669 Manual adjustment. Turn nut on deck eyebolt to adjust belt tension. Note: Belt deflection or movement should be approximately 1/4” when measured at mid-point between pulleys. Periodically inspect both belt and idler systems.
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 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.
CARE AND MAINTENANCE CAUTION HOT oil may cause burns. Allow engine to cool before draining oil. OIL FILL: 1. Clean any spilled oil from engine and chassis. 2. Refill engine with type, and quantity of oil recommended by the engine manufacturer in engine literature. NOTE: Engine oil changes on the BLACK BEAR™ 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.
CARE AND MAINTENANCE HYDROSTATIC TRANSMISSION FLUID & FILTER SERVICE: Dirt or water in fluid can ruin the hydrostatic transmissions. SERVICE INTERVALS: 1. Initial filter service - 100 hours 2. Every 500 hours or once a year thereafter. RECOMMENDED FLUID: All temperatures Dixon Blue™ 15W-50 Synthetic Hydrostatic Fluid ~or if not available~ Normal Operating Temperatures - 20W50 engine oil Cold climate usage - 10W40 engine oil Use engine oil with an API classification of SG/CD.
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 Dixon BlueTM 15W-50 Synthethic Hydrostatic Fluid or a quality SAE 20W-50 motor oil. DO NOT OVERFILL. When checking the oil level, be very careful to keep the reservoir clean.
CARE AND MAINTENANCE NEUTRAL ADJUSTMENT 1. Lift seat. 2. Block up the unit so that the drive wheels are off the ground. Remove rear tires. 3. Loosen jam nuts on both ends of the control rod coupler. Note: The rear jam nuts are left hand threads. 4. With steering control arms in the “out” neutral position, start the engine and run at fast idle. 5. Adjust the neutral position by turning the control rod coupler until the hubs do not rotate. 6.
CARE AND MAINTENANCE MOWER DECK LEVELING PROCEDURE: There are a total of (4) slots which will control the attitude or pitch of the mower deck. Deck should be level or pitched slightly higher in rear. A. Place the mower on a smooth level surface with front casters positioned t owards deck. Check tire pressures to insure the mower has a correct stance.
CARE AND MAINTENANCE MOWER DECK LEVELING PROCEDURE (continued): D. Turn both outer blades to align with the deck in frontto-rear manner. Reposition rear mounting bolts up or down until rear of mower deck is positioned level to 1/8” higher in the rear than the side-to-side measurement. 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 sideto-side measurement.
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.
CARE AND MAINTENANCE MOWER DECK REMOVAL: 1. Remove mower deck drive belt from clutch. To relieve belt tension, loosen nut on tensioner eyebolt. 2. Move deck into lowest cut position and support deck with blocks. 3. Remove nut from each of the four hanger bolts (suspended from chains). Remove hanger bolts from deck slots. 4. Remove hardware attaching trailer arms to rear of deck. 5. Slide deck from beneath chassis. 6. Reverse procedure to re-install deck to chassis.
TROUBLESHOOTING 1.
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.
STANDARD SERVICE PARTS LIST Blades *Standard Lift Fusion - 10614 Hi Lift Fusion - 10954 Lo Lift Fusion - 10972 Gator Fusion - 10615 *Factory installed Belts Engine to Mower Deck - P/N 10669 Engine to Hydros - P/N 10923 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.
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.
Dixon® and ZTR® are registered trademarks of Dixon Industries, Inc. 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 INDUSTRIES, INC. P.O. Box 1569 Coffeyville, Ks 67337-0945 620-251-2000 BLACK BEAR™ Part No.
