Dixon 2005 Kodiak ZTR Series, Safety Instructions And Operator'S Manual

Page 1: ...Model Year 2005 Safety Instructions Operator s Manual...

Page 2: ...ead 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...

Page 3: ...AFETY WARNING 4 15 WARRANTY 16 17 SPECIFICATIONS 18 19 SEAT ADJUSTMENT 20 CONTROLS 21 24 OPERATION INSTRUCTIONS 25 35 CARE MAINTENANCE 36 48 STANDARD SERVICE PARTS LIST 49 50 TROUBLESHOOTING 51 52 KOD...

Page 4: ...un Over Back Over 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 understan...

Page 5: ...ntly 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 deat...

Page 6: ...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 operate the mower without either the en...

Page 7: ...g 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...

Page 8: ...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 repla...

Page 9: ...move obstacles such as rocks tree limbs wires and other foreign objects that can be thrown by mower blades Watch for holes ruts roots and bumps Uneven terrain could overturn the mower Tall grass can h...

Page 10: ...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 SLOPE OPERA...

Page 11: ...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 g...

Page 12: ...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...

Page 13: ...used 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 pra...

Page 14: ...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 They may fall...

Page 15: ...ents 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 F...

Page 16: ...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 D...

Page 17: ...via 8 position lift handle BLADE DRIVE Electric clutch DRIVE SYSTEM Each rear wheel is independently driven by a Parker 10cc pump and TE0230 wheel motor ENGINE Each mower is powered with either a 19HP...

Page 18: ...18 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 Seat Slide Adjuster...

Page 19: ...ward 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 rea...

Page 20: ...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...

Page 21: ...cal 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 LEVERS Located on...

Page 22: ...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 1 Read engine manufact...

Page 23: ...ted for a period of time 3 Insert ignition key and turn to start position When engine starts release ignition key Key will return to run position 4 Return choke to off position if applicable 5 Move th...

Page 24: ...ve switch b Put parking brake in ON position c 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...

Page 25: ...a 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 I...

Page 26: ...he 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 Attempt...

Page 27: ...peller are still turning 8 Alternate mower direction This will evenlydisperse the mulched grass clippings over the lawn for even fertilization If the mulching quality of the mower does not seem to be...

Page 28: ...nderside of the deck and the attachment chutes Empty bags often to prevent plugging 4 If the grass is tall place the mower deck cut height selector in the top or second notch Initially overlap cutting...

Page 29: ...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...

Page 30: ...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...

Page 31: ...blades throughout the cutting season As a rule 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 c...

Page 32: ...ttempt 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...

Page 33: ...se Clean grass from hydrostat fans before each use Clean grass debris from muffler manifold area before each use Clean grass under deck after each use Check tire pressure every 10 hours Inspect blades...

Page 34: ...DANGEROUS DO NOT USE BLADE IN THIS CONDITION When notch starts discard blade New Blade Check sharpness of mower blades after every 10 hours of operation Observe proper blade position prior to removal...

Page 35: ...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 f...

Page 36: ...ires 13 x 5 00 6 16 21 lbs Rear tires 20 x 10 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 eac...

Page 37: ...e 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 3 4 4...

Page 38: ...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 t...

Page 39: ...ngine 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...

Page 40: ...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 c...

Page 41: ...p 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 reservoir and hydrosta...

Page 42: ...re left hand threads 4 With steering control arms in the out neutral position start the engine and run at fast idle 5 Adjusttheneutralpositionbyturningthecontrolrod until the wheels do not rotate 6 Re...

Page 43: ...eat for opposite side 4 Engage parking brake and lower seat frame Release parking brake and swing control levers in If wheel creeps repeat steps 1 and 2 5 Stop engine and remove rear of machine from j...

Page 44: ...s toinsurethemowerhasacorrectstance Inflatetiresas required Front 16 21 lbs maximum Rear 8 14 lbs maximum NOTE Toinsureaccuracyoflevelingprocedure mower deckdrivebeltmustbeinstalledpriortoleveling dec...

Page 45: ...ersandtheleftrearadjuster Move the right rear adjuster and take out the slack which will be present by turning adjuster locknutup E Confirm measurements once again Blade tips should be level in a side...

Page 46: ...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...

Page 47: ...o 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 2 Remove front an...

Page 48: ...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 ENGINE STARTS BUT CUTS OUT Water in fuel drain old fuel r...

Page 49: ...ator not on 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 foreign material clean unde...

Page 50: ...nal equipment filters Refer to the Engine Operator s Manual or ask your dealer for correct replacement parts STANDARD SERVICE PARTS LIST Blades Hi Lift Fuson P N 13919 Super Hi Lift Fusion P N 13868 H...

Page 51: ...NFORMATION 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 Ks 620 251 2000 Fax 620...

Page 52: ...s Inc DIXON INDUSTRIES INC P O Box 1569 Coffeyville Ks 67337 0945 620 251 2000 KODIAK Part No 18124 0804 The engine exhaust from this product contains chemicals known to the State of California to cau...