Dixon Black Bear, Safety And Operating Manual

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

Page 2: ...d 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 Th...

Page 3: ...e 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...

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: ...ing 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...

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 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 OPERAT...

Page 11: ...er 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 gro...

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: ...applications c Warranty applies tonew andunused mowers andistransferable 3 Lifetimewarranty on all frames andleading edge of all fabricated welded decks 4 All Dixon warranty must be accomplished by a...

Page 17: ...osition 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 Kawasa...

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: ...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: ...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 o...

Page 21: ...sport 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 hol...

Page 22: ...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 LEVER Located on c...

Page 23: ...l 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 Read engine manufac...

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 Mo...

Page 25: ...e 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 26: ...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 27: ...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 28: ...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 29: ...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 30: ...tacles 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 Di...

Page 31: ...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 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 c...

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...

Page 34: ...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 35: ...en 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 positi...

Page 36: ...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 37: ...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 mow...

Page 38: ...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...

Page 39: ...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 40: ...ine 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 t...

Page 41: ...g 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 provi...

Page 42: ...c 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...

Page 43: ...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...

Page 44: ...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 de...

Page 45: ...ide 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 bladet...

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: ...nsioner 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 har...

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: ...your engine investment use only original equipment filters Refer to the Engine Operator s Manual or ask your dealer for correct replacement parts STANDARD SERVICE PARTS LIST Blades Standard Lift Fusi...

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: ...Inc DIXONINDUSTRIES INC P O Box 1569 Coffeyville Ks 67337 0945 620 251 2000 BLACK BEAR Part No 11249 0605 The engine exhaust from this product contains chemicals known to the State of California to ca...