Dixon ZTR44/968999565 - Manual

English - 6 SYMBOLS AND DECALS These symbols are found on the machine and in the operator’s manual. Study them carefully so that you know what they mean. Used in this publication to notify the reader of a risk of personal injury or death , particularly if the reader should neglect to follow instruct...

English - 8 SAFETY Safety Instructions These instructions are for your safety. Read them carefully. IMPORTANT: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROWING OBJECTS. FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT INSERIOUS INJURY OR DEATH. WARNING! This...

English - 10 SAFETY Personal Safety Equipment • Make sure that you have first aid equipmentclose at hand when using the machine. • Never use the machine when barefoot. • Always wear protective shoes or boots,preferably with steel toe caps. • Always wear approved protective glasses • or a full visor ...

English - 11 SAFETY • Use extra care while operating machine withgrass catchers or other attachments; theycan affect the stability of the machine. Do notuse on steep slopes. • Do not try to stabilize the machine by puttingyour foot on the ground. • Do not mow near drop-offs, ditches, orembankments. ...

English - 12 SAFETY Maintenance Safe Handling of Gasoline To avoid personal injury or property damage, useextreme care in handling gasoline. Gasoline isextremely flammable and the vapors are explosive. • Extinguish all cigarettes, cigars, pipes, andother sources of ignition. • Use only approved gaso...

English - 13 SAFETY General Maintenance • Never operate machine in a closed area. • Keep all nuts and bolts tight to be sure theequipment is in safe working condition. • Never tamper with safety devices. Checktheir proper operation regularly. • Keep machine free of grass, leaves, or otherdebris buil...

English - 14 SAFETY • Ensure that nuts and bolts, especially thefastening bolts for the blade attachments, areproperly tightened, torqued and that theequipment is in good condition. • Do not modify safety equipment. Checkregularly to be sure it works properly. Themachine must not be driven with defe...

English - 16 SAFETY Roll over Protection system (ROPS) The ROPS increases the basic weight of the unit by 42lbs/19 kg. The ROPS on the US units are standard, onthe European units is the ROPS an accessory. • Do not use ROPS as a lifting, attaching oranchoring point. • Do not use ROPS for wrecking or ...

CONTROLS English - 17 Controls This operator’s manual describes the Dixon Zero TurnRider. The rider is fitted with a Kawasaki four-stroke V-Twin engine developing 17-19 horse power. Transmission from the engine is made via two belt-driven hydraulic pumps, which in turn drive a hydraulicmotor for eac...

CONTROLS English - 18 1. Motion Control Levers The machine’s speed and direction are continuouslyvariable using the two steering controls. The steeringcontrols can be moved forward or backward about aneutral position. Furthermore, there is a neutralposition, which is locked if the steering controls ...

CONTROLS English - 19 Seat adjustment 8050-165 2. Seat adjustment lever The seat can be adjusted lengthways. When makingadjustments, sit on the seat. Slide the lever to the sideand maneuver seat to appropriate placement andrelease lever. 3. Bypass Linkages When pushing or pulling the mower, be sure ...

CONTROLS English - 21 5. Hour Meter The hour meter displays the total operating time. It will flash CHG OIL (Change Oil) at 50 hour intervals.The flash duration is one hour before and one hourafter the interval. The CHG OIL icon will come on andshut off automatically. The hour meter cannot bemanuall...

CONTROLS English - 23 12. Mower Deck Cut Height Lift Lever Located to the right and front of the operator, the liftlever controls the cutting height. The deck cuttingheight is obtained by pressing the foot pedal forward tolift the deck. To lower the deck, apply pressure to thetop side of the foot pe...

English - 24 OPERATION Operation Read “Safety Instructions” section and following pages, if you are unfamiliar with the machine. Training Zero turn mowers are far more maneuverable than typical riding mowers due to their unique steering capabilities. We suggest that this section be reviewed in its e...

English - 25 OPERATION Before Starting • Read the sections Safety Instructions andControls before starting the machine. • Perform the daily maintenance beforestarting (see Maintenance Schedule in theMaintenance section). • Check that there is sufficient fuel in the fueltank. • Adjust the seat to the...

English - 26 OPERATION • Move the steering controls outward to thelocked (outer) neutral position. • Move the throttle to the middle position. • If the engine is cold, the throttle controlshould be pushed forward to its chokeposition. • Press in and turn the ignition key to the startposition. Steeri...

English - 29 OPERATION Running 1. Release the parking brake by moving the lever downward.Your mower is equipped with an operatorpresence system. When the engine isrunning, any attempt by the operator to leavethe seat without first setting the parking brakewill shut off the engine. 2. Move the steeri...

English - 30 OPERATION In order, for example, to turn right whilemoving forward, move the right controltowards the neutral position. The rotation ofthe right wheel is reduced and the machineturns to the right.Turning on the spot can be achieved bymoving one control backward (behind theneutral positi...

English - 31 OPERATION Mowing Tips • Observe and flag rocks and other fixedobjects to avoid collisions. • Begin with a high cutting height and reduceit until the desired mowing result is attained.The average lawn should be cut to 2½" (64mm) during the cool season and over 3" (76mm) during th...

English - 32 OPERATION Stopping the Engine Allow the engine to idle a minute in order to attainnormal operating temperature before stopping it, if ithas been worked hard. Avoid idling the engine forlonger periods, as there is a risk of the spark plugsfouling. • Disengage the mower deck by depressing...

English - 33 OPERATION Moving by Hand When pushing or pulling the mower, be sure to engagethe IZT (Integrated Zeroturn Transaxle) bypasslinkages. • Always turn off engine before engaging ordisengaging the hydro release. Neverattempt to adjust the bypass linkages with theengine running. • The hydro r...

English - 34 Daily Weekly At Maintenance Interval Least In Hours Once Each Year Maintenance Page Before After 25 50 100 300 Check the parking brake z Check the engines oil level (every refueling) z Check the safety system z Check for fuel and oil leakages ‹ Check/clean the engine’s cooling air intak...

English - 35 Daily Weekly At Maintenance Interval Least In Hours Once Each Year Maintenance Page Before After 25 50 100 300 Check/adjust throttle cable z

English - 36 Battery Your mower is equipped with a maintenance freebattery and does not need servicing. However, periodiccharging of the battery with an automotive type batterycharger will extend its life. • Keep battery and terminals clean. • Keep battery bolts tight. • Recharge at 6-10 amperes for...

English - 37 Ignition System The engine is equipped with an electronic ignitionsystem. Only the spark plug requires maintenance. For recommended spark plug, see Technical Data. 1. Remove the ignition cable boot and clean around the spark plug. 2. Remove the spark plug with a spark plug socket wrench...

English - 38 Checking the Engine’s Cooling Air Intake Check that the engine’s cooling air intake is free fromleaves, grass, and dirt. If the cooling air intake is clogged, engine coolingdeteriorates, which can lead to engine damage. Checking and Adjusting the Throttle Cable Check that the engine res...

English - 39 Replacing the Air Filter If the engine seems weak or runs unevenly, the airfilter may be clogged. If run with a dirty air filter, thespark plugs can become fouled, disrupting operation. For this reason, it is important to replace the air filterregularly (see the heading Maintenance Sche...

English - 40 4. Tap the paper filter against a fixed surface to remove dust. If the paper filter is still dirty, itmust be replaced. Refit the air filter as follows: 1. Check that the seal on the bottom of the paper filter is whole. 2. Mount the paper filter in the air filter housing and tighten the...

English - 41 Checking Tire Pressures All four tires should have a pressure of 15 psi / 103 kPa /1 bar. Checking the Parking Brake Visually check that no damage is found on the lever,linages, or switch belonging to the parking brake.Perform a stand still test and check that there is abraking action. ...

English - 42 Deck belt removal 1. Park on a level surface. Apply parking brake. 2. Lower the deck into the lowest cutting position. 3. Remove bolts from belt shields and remove shields. 4. Remove any dirt or grass that may have accumulated around the cutter housings andentire deck surface. 5. Carefu...

English - 43 Pump Belt To replace EZT (E-Series Zeroturn Transaxle) belt Park the mower on a level surface. Engage the parkingbrake. EZT belt removal NOTE: Be careful not to damage the fan blades onthe EZT´s as this can affect cooling or damage theEZT´s • Remove the deck belt (see Deck Belt Removal ...

English - 44 Blade replacement • Remove blade bolt by turning counterclockwise. • Install new or re-sharpened blade with stamped “GRASS SIDE” facing towardsground/grass (down) or “THIS SIDE UP”facing deck and cutter housing. • Install and tighten blade bolt securely.Torque blade bolt to 27-35 ft/lb ...

English - 45 Adjusting the Mower Deck Check the tire pressure before adjustment of themower deck. See “Checking Tire Pressure” inMaintenance section. Faulty mower deck adjustments will cause an uneven mowing result. To level deck Adjust the deck while the mower is on a level surface.Make sure the ti...

English - 46 MAINTENANCE To adjust anti-scalp rollers Deck has anti-scalp rollers. Anti-scalp rollers are properly adjusted when they arejust slightly off of the ground when the deck is at thedesired cutting height in the operating position. Anti-scalp rollers then keep the deck in the proper positi...

English - 47 MAINTENANCE Cleaning and Washing Regular cleaning and washing, especially under themower deck, will increase the machine’s lifespan.Make it a habit to clean the machine directly after use(after it is cooled), before the dirt sticks. Do not spray water on the top of the mower deck. Useco...

English - 48 General Remove the ignition key to prevent unintentional movements during lubrication. When lubricating with an oil can, it must be filled with engine oil. When lubricating with grease, unless otherwise stated, use a high grade molybdenum disulfide grease. For daily use, the machine sho...

English - 49 Lubricating the Cables If possible, grease both ends of the cables and move the controls to end stop positions when lubricating. Refit therubber covers on the cables after lubrication. Cables with sheaths will bind if they are not lubricated regularly. If acable binds, it can disrupt op...

English - 50 4. Deck outer spindle Lubricate using a grease gun, one zerk, each side 2-3strokes. Use only good quality bearing grease. 5. Engine Oil Changing the Engine Oil The engine oil should be changed for the first time after5-8 hours of operation. Thereafter, it should bechanged every 50 hours...

English - 51 Checking the Oil Level Check the oil level in the engine when the machine isstanding level and the engine is stopped. Remove the dipstick, wipe it clean, and then replace it. The dipstick should be screwed into place. Take the dipstick out again and read the oil level. The oil level sho...

English - 52 6. Changing the Engine Oil Filter 1. Drain the engine oil in accordance with thework description under the heading EngineOil/Change Engine Oil. 2. Remove the oil filter. If necessary, use afilter remover. 3. Wipe new, clean engine oil onto the sealfor the new filter. 4. Mount the filter...

English - 53 7. Drain old oil filters of all free flowing oil priorto disposal. Place used oil in appropriatecontainers and dispose of it in accordancewith laws in your area. 8. Remove the top port plug (see illustration)from the left side and right side of thetransaxles prior to filling with oil. T...

English - 54 Purging Procedures Due to the effects air has on efficiency in hydrostaticdrive applications, it is critical that it is purged from thesystem. These purge procedures should be implemented anytime a hydrostatic system has been opened to facilitatemaintenance or any additional oil has bee...

English - 55 Trouble Shooting Guide Problem Cause The engine will not start. • The blade switch is engaged. • The steering controls are not locked in the neutralposition. • The driver is not sitting in the driver’s seat. • The parking brake is not activated. • The battery is dead. • Contamination in...

English - 58 STORAGE Storage Winter Storage At the end of the mowing season, the machine shouldbe readied for storage (or if it will not be in use forlonger than 30 days). Fuel allowed to stand for longperiods of time (30 days or more) can leave stickyresidues that can plug the carburetor and disrup...

English - 59 SCHEMATIC FRONT HALF OF WIRING HARNESS ALL MODELS CODE COLOR A RED B RED C RED D BLLUE E BLUE F WHITE G WHITE H WHITE J WHITE K WHITE L WHITE M WHITE N RED/WHT P RED/WHT R YELLOW S YELLOW T YELLOW U YELLOW V YELLOW W GREEN X GREEN Y GREEN Z WHT/GRN AA WHT/GRN AB WHT/GRN AC WHT/GRN AD BR...

English - 62 TECHNICAL DATA Engine Manufacturer Kohler Kohler Type Command Pro Command Pro Power 18 hp 18 hp Lubrication Pressure with oil filter Pressure with oil filter Oil capacity excl filter 1.9 (1.8 liters) 1.9 (1.8 liters) Oil capacity incl filter 2 qt (1.9 liters) 2 qt (1.9 liters) Engine oi...

English - 63 TECHNICAL DATA Equipment Cutting width 34" 44" Cutting height 1.5" - 4.5" 1.5" - 4.5" Uncut circle 0 0 Number of blades 2 3 Blade length 17.38" 15.25" Nose rollers Yes Yes American Craftsmen Seat Standard Standard Hinged armrests Yes Yes Hour meter Standa...

English - 70 TECHNICAL DATA Accessories Collection system Torque Specifications ·Engine crankshaft bolt 50 ft/lb (67 Nm) ·Deck pulley bolts 45 ft/lb (61 Nm) ·Lug nuts 75 ft/lb (100 Nm) ·Blade bolt 45-55 ft/lb (60-75 Nm) ·Standard ¼” fasteners 9 ft/lb (12 Nm) ·Standard 5/16" fasteners 18 ft/lb (2...

English - 71 CONFORMITY CERTIFICATES Conformity Certificates USA requirements Labels are placed on the engine and/or in the engine compartment stating that the machine will fulfill therequirements. This is also applicable to special requirements for any of the states, (Californian emission rulesetc....

English - 72 SERVICE JOURNAL Service Journal Action Date, mtr reading, stamp, sign Delivery Service 1. Charge the battery. 2. Adjust the tire pressure of all wheels to 15 PSI (1 bar). 3. Mount the steering controls in the normal position. 4. Connect the contact box to the cable for the seat’s safety...

English - 73 SERVICE JOURNAL After the First 5-8 Hours 1. Change engine oil.

English - 75 SERVICE JOURNAL Action Date, mtr reading, stamp, sign 50-Hour Service 1. Perform the 25-hour service. 2. Clean/replace the air cleaner’s filter cartridge (paper filter) (shorter intervals for dusty operating conditions). 3. Change engine oil. 4. Lubricate according to lubrication chart....

English - 76 Action Date, mtr reading, stamp, sign 100-Hour Service 1. Perform the 25-hour service. 2. Perform the 50-hour service. 3. Change the engine oil filter. 4. Clean/replace the spark plugs. 5. Replace the fuel filter. 6. Clean the cooling fins on the engine and transmission. 7. Check V-belt...

English - 77 Action Date, mtr reading, stamp, sign 300-Hour Service 1. Inspect the machine. Come to agreement with the customer as to which additional work is to be carried out. 2. Perform the 25-hour service. 3. Perform the 50-hour service. 4. Perform the 100-hour service. 5. Check/adjust the mower...

English - 78 SERVICE JOURNAL Action Date, mtr reading, stamp, sign At Least Once Each Year 1. Clean the engine’s cooling air intake (25 hours). 2. Replace the air cleaner’s pre-filter (foam) (300 hours). 3. Replace the air filter’s paper cartridge. 4. Change the engine oil (50 hours). 5. Replace the...