Dixon Black Bear 11249-106, Safety And Operating Manual

Page 1: ...Safety Instructions Operator s Manual BLACK BEAR ZTR ...

Page 2: ...ad 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 The information contained in this manual applies to all Dixon Black Bear ZTR mowers See your authorized Dixon dealer for warranty service parts and repairs or to answer any questions you may have about...

Page 3: ...ge SAFETY WARNING 4 15 WARRANTY 16 SPECIFICATIONS 17 SEATADJUSTMENT 18 CONTROLS 19 22 OPERATION INSTRUCTIONS 23 33 CARE MAINTENANCE 34 47 TROUBLESHOOTING 48 49 STANDARD SERVICE PARTS LIST 50 BLACK BEAR Part Number 11249 106 ...

Page 4: ...Run 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 understand this manual to prevent injuries ...

Page 5: ...ently 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 CAUTION highlighted in yellow indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe p...

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 entire grass catcher or the deflector in place This will decrease the possibility of injury from objects being thrown by the mower blades Never carry passengers They may fall off and become seriously i...

Page 7: ...ning To avoid personalinjury from accidentalclutch engagement 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 Slow down before turning to reduce the risk of tip over Watch for traffic when operating near or crossingroadways Use extra care when loading or unloading the ...

Page 8: ...r ability to operate the riding mower 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 replace safety instruction labels as needed GENERAL OPERATION continued The engine exhaust from this product contains chemicals known to the State of California to caus...

Page 9: ...emove 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 hide such obstacles Use slow speed Tires may lose traction on slopes even though the brakes are functioning properly Avoid starting or stopping on a slope If tires lose traction disengage the blades a...

Page 10: ...e caution when operatingthe 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 OPERATION continued DO continued Failure to observe the following safety instructions could result in serious injury or death ...

Page 11: ...ver 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 ground Do not use grass catcher or other attachments on steep slopes The added weight may change the stability of the mower thus creating the potential for tip over Failure to observe the following safe...

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 vapors have dissipated Wipe up spilled fuel and dispose of waste properly Iffuelisspilled onclothing changeclothingimmediately Before storing allow mower to cool Clean fuel and oil spillage Never st...

Page 13: ...aused 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 practical remove fuel powered equipment from the truck or trailer and refuel it on the ground If this is not possible refuel such equipment on a trailer with a portable container rather than from a fuel...

Page 14: ...e 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 off and be seriously injured or interfere with safe mower operation Never allow children to operate the mower Use extra care when approaching blind corners shrubs trees or other objects that may obsc...

Page 15: ...ments 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 Frequently check components Replace with original equipment parts when necessary Mower blades are sharp and can cut Wrap blades or wear gloves and use extra caution when servicing them Batteries conta...

Page 16: ... Warranty applies to new and unused mowers and is transferable 3 Lifetime warranty on all frames and leading edge of all fabricated welded decks 4 All Dixon warranty must be accomplished by authorized Dixon dealers and in accordance with Dixon warranty policy and allowances All warranty claims must be submitted to Dixon Industries for approval 5 Warranty labor reimbursement to dealers based on pub...

Page 17: ...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 16HP Kawasaki or 18HP Kohler engine overhead valve air cooled gasoline full pressure lubrication with oil filter STARTING SYSTEM Electric by key switch operation with safety interlocks on parking brake and blad...

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 ...

Page 19: ...oward 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 To turn on mower s own axis zero turning radius stop and move one lever to reverse position and the other to forward position BRAKING To brake mower move both levers in direct...

Page 20: ...g brake is engaged while the control levers are in the drive position 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 Note Always set parking brake before dismounting Release parking brake before moving mower CAUTION ...

Page 21: ...nsport The two holes at the front of the quadrant are for 1 1 2 and 1 3 4 cut heights The four holes along the bottom of the quadrant are for one inch cut height increments 2 to 5 The second row of holes from the bottom are for an additional 1 4 of cut height over its mating one inch increment 2 1 4 to 5 1 4 The third row of holes from the bottom are for an additional 1 2 of cut height over its ma...

Page 22: ...ical 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 Throttle control for engine speed Choke for engine starting Throttle control should be set to MAXIMUM or wide open setting to insure adequate cooling of the engine an...

Page 23: ...ER dismount mower without applying parking brake or stopping engine 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 manufacturer s operating and maintenance instructions 2 Read and observe all safety instructions on your mower and in the manual 3 Check engine oil 4 Check fuel cap to be...

Page 24: ... operated 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 throttle to maximum speed position 6 Release parking brake 7 Swing levers inward 8 Operate mower per CONTROL instructions on Page 19 CAUTION Do not operate the engine in an enclosed area due to th...

Page 25: ...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 the mower until the system has been checked and repaired by an Authorized Dixon Dealer TESTING OF SAFETY INTERLOCK SYSTEMS Failure to observe the following testing instructions could result in seriou...

Page 26: ...n 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 If any safety check fails do not operate the mower until the system has been checked and repaired by an Authorized Dixon Dealer Failure to observe the following testing instructions could result in se...

Page 27: ...the 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 Attempting to cut more grass will result in the deck plugging and cause the engine to stall 4 It may be necessary to cut the lawn twice to achieve acceptable mulching performance especially on first cutting...

Page 28: ...mpeller 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 satisfactory try one or more of the following tips a Raise the height of cut setting on your mower b It may be necessary to cut your grass more frequently c Operate the mower at a slower ground speed...

Page 29: ...underside 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 swaths instead of a full swath with each pass 5 Keep the underside of the mower deck clean Frequent removal of dried grass and dirt will greatly assist in bagging of the clippings Never under any ci...

Page 30: ...stacles 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 muffler of the engine Fire could result Disengage blade and stop engine prior to clearing grass from either the discharge chute or grass catcher components Do not operate the mower with the grass catching attachment partially removed Operato...

Page 31: ...t 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 cutting swaths instead of a full swath with each pass Some applications may require a second cutting 4 Keep the underside of the mower deck clean Frequent removal of dried grass and dirt will allow t...

Page 32: ... 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 cut heights are based on adequate moisture conditions and normal thatch build up in a healthy lawn Some locations and applications may require slightly different cut heights If in doubt consult your l...

Page 33: ... attempt to move the lever with the engine running The hydro release valves are located below the seat on the front side of the hydro pumps To access the release valves lift the seat frame assembly use a 5 8 wrench to rotate bolt counter clockwise two full turns to disengage pump Repeat procedure for opposite pump To engage rotate each pump bolt clockwise until bolt is snug NOTE Before pushing or ...

Page 34: ...use 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 for sharpness every 10 hours Check hydrostatic transmission fluid every 25 hours Clean air filter element every 25 hours Check traction drive idler adjustment every 50 hours Grease all zerks every 5...

Page 35: ...hen worn excessively 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 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 Tighten b...

Page 36: ...r 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 first and reconnect last Charge battery Note Your Dixon mower comes equipped with a quick disconnect harness for the optional Dixon Battery Manager The Dixon Battery Manager maintains the proper charg...

Page 37: ...1 lbs Rear tires 23 x 8 5 12 8 14 lbs Lug nuts or lug bolts should be checked regularly for tightness LUBRICATION CHASSIS grease zerks LOCATIONS front wheels front caster tubes control lever pivots mower deck hubs deck lift shafts deck trailer arms brake shafts SERVICE INTERVALS Every 50 hours of operation or once per season RECOMMENDED Name brand wheel bearing GREASE or multi purpose grease 3 pum...

Page 38: ...r condition BELT TENSION Engine to Mower Deck Belt P N 10669 34 P N 11305 44 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 ...

Page 39: ...e 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 Change oil filter 6 Fill with oil see steps on next page NOTE Refer to engine manufacturer s recommenda tions for freque...

Page 40: ...gine 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 Oil Filters can be obtained from your authorized engine dealer 3 The use of any other oil ftiler may cause damage to the engine PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CE...

Page 41: ...ng Temperatures 20W50 engine oil Cold climate usage 10W40 engine oil Use engine oil with an API classification of SG CD Dixon Blue 15W 50 Synthetic Hydrostatic Fluid is specifically formulated to provide excellent all climate performance and extended time between oil changes FLUID FILTER P N 18045 IMPORTANT The fluid filter is a special design for use on vacuum or suction oil flow systems DO NOT U...

Page 42: ...ic 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 Change the oil in the reservoir and hydrostat transmission oil filter after the first 100 hours of use Then every 500 hours after that Remove the filter and be sure all oil has drained from the reservoir Replace with a new OEM filter P N 18045 and Dixon Blu...

Page 43: ...e left hand threads 4 With steering control arms in the out neutral position start the engine and run at fast idle 5 Adjusttheneutralpositionbyturningthecontrolrod coupler until thehubs do notrotate 6 Re tighten the jam nuts against the control rod couplerandchecktoseethatthedrivewheelsare notturning 7 Repeat steps 3 6 for the other side 8 Shut off engine before reinstalling rear tires and removin...

Page 44: ...6 21 lbs maximum Rear 8 14 lbs maximum NOTE Toinsureaccuracyoflevelingprocedure mower deckdrivebeltmustbeinstalledpriortoleveling deck B Wear heavy gloves Turn each outer blade tip to align with the deck or in a side to side manner C Measure from the floor surface up to the bottom of the blade tip on the discharge side of the mower deck Retain this measurement Move to the opposite side checkthatme...

Page 45: ...side to side measurement E Confirm measurements once again Blade tips shouldbelevelinaside to sidemanner Intherear blade tips should be levelto 1 8 higher than side to sidemeasurement Inthefront bladetipsshould be level to 1 8 lower than side to side measurement NOTE This will place the mower deck in a base measurementposition Additionaladjustmentmay be required to achieve desired cut for the type...

Page 46: ...g 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 are hot they will draw moisture inside as they dry and cause corrosion SERIAL NUMBERS The serial number is located on frame at rear of engine WARRANTY Refer to warranty information page 16 PARTS SER...

Page 47: ...ensioner 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 armstorear of deck 5 Slide deck from beneath chassis 6 Reverse procedure to re install deck to chassis ...

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 replace with new fuel Clogged fuel line check fuel filter Fuel tank vent plugged clean fuel vent Faulty fuel pump consult dealer 5 ENGINE OVERHEATED Air intake screen or fins clogged clean intake scre...

Page 49: ...rator 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 under deck 9 DRIVE SYSTEM Mower pulls to side check tire inflation adjust control linkage Mower creeps in neutral adjust control linkage Low on power check belt tension 10 CUT QUALITY Cut uneven left to ...

Page 50: ...Manual or ask your dealer for correct replacement parts STANDARD SERVICE PARTS LIST 34 Black Bear Blades Hi Lift Fusion 10954 Factory Installed Standard Lift Fusion 10614 Lo Lift Fusion 10972 Gator Fusion 10615 Belts Engine to Mower Deck P N 10669 Engine to Hydros P N 10923 44 Black Bear Blades Hi Lift Fusion 10710 Factory Installed Standard Lift Fusion 10709 Gator Fusion 10708 Belts Engine to Mow...

Page 51: ...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 Box 1569 Coffeyville Ks 620 251 2000 Fax 620 251 4117 ...

Page 52: ...s Inc DIXONINDUSTRIES INC P O Box 1569 Coffeyville Ks 67337 0945 620 251 2000 BLACK BEAR Part No 11249 106 The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WARNING ...