Dixon Lawn Mower 21 KAW 968999576 User Guide

KODIAK® ZTR®  
Operator’s manual  
KODIAK 52, 21 KAW/968999576,  
KODIAK 52, HONDA/968999577,  
KODIAK 52, 20 KOH/968999578,  
KODIAK 52, 25 KOH/968999579,  
KODIAK 60, 25 KOH/968999580,  
KODIAK 60, 26 B&S/968999581  
Please read the operator’s manual carefully  
and make sure you understand the  
instructions before using the unit.  
English  
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TABLE OF CONTENTS  
Page  
SAFETY & WARNING....................................4-15  
WARRANTY........................................................16  
SPECIFICATIONS.............................................17  
SEATADJUSTMENT.........................................18  
CONTROLS..................................................19-21  
OPERATION INSTRUCTIONS....................22-32  
CARE & MAINTENANCE............................33-45  
TROUBLESHOOTING..................................46-47  
STANDARD SERVICE PARTS LIST...............48  
KODIAK®  
Part Number 114518Rir - 11/07/06  
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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.  
Blade Contact  
Tip Over  
Run Over  
Back Over  
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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.  
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 practices.  
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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.  
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 injured or interfere with safe operation of the  
mower.  
Mowing in reverse is not recommended because it is  
difficult to maintain a clear vision of the mowing path.  
However, should it become necessary to back up,  
remember to look down and behind before and while  
backing.  
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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.  
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 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 crossing road-  
ways.  
Use extra care when loading or unloading the mower into  
a trailer or truck. Push, do not ride the mower when  
loading and unloading.  
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WARNING  
Failure to observe the following safety instructions  
could result in serious injury or death.  
GENERAL OPERATION (continued):  
Never dismount mower without applying parking brake  
or stopping engine.  
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.  
To protect against possible tip-over, follow the  
manufacturer’s recommendation for wheel weights,  
counterweights and R.O.P.S.  
Maintain or replace safety & instruction labels as  
needed.  
The engine exhaust from this product contains chemicals known to the State of  
California to cause cancer, birth defects or other reproductive harm.  
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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.  
Remove 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 and proceed slowly  
down the slope.  
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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. Discontinue mowing the  
slope!  
When operating on slopes over 15 degrees, the  
unit must be equipped with an approved, dealer-  
installed R.O.P.S. and Seat Belt Kit.  
R.O.P.S. should be in the upright, operating  
position (not folded-down) at all times when  
operating mower.  
Always use seat belt on any mower equipped with  
a R.O.P.S.  
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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 embank-  
ments. 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.  
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 (over 15 degrees). The added weight  
may change the stability of the mower thus creating  
the potential for tip-over.  
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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.  
To reduce fire hazard, keep 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.  
If fuel is spilled on clothing, change clothing immediately.  
Before storing, allow mower to cool. Clean fuel and  
oil spillage.  
Never store the mower or fuel container inside a  
building where there is an open flame.  
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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.  
Use care when backing to avoid pushing the grass  
bags into the frame or “hot” exhaust muffler of the  
engine. Fire could result.  
To prevent fire and explosion caused 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 dispenser  
nozzle.  
If a fuel dispenser nozzle must be used, keep the  
nozzle in contact with the rim of the fuel tank or  
container opening at all times until fueling is complete.  
Do not use a nozzle lock-open device.  
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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.  
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 obscure vision.  
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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.  
Never make adjustments 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 contain sulfuric acid. To prevent burns, avoid  
contact with skin, eyes and clothing.  
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®
®
DIXON ZTR PRO SERIES COMMERCIAL/RESIDENTIAL WARRANTY POLICY  
Black BearTM, Kodiak®, MountainKodiak®, Kodiak® Diesel, 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. First two years - 100% parts and labor subject to the conditions and limitations described herein  
with the exception of non-covered items specified below.  
b. Third year - limited to 100% parts cost as shown in the current Dixon® Parts Price List and  
subject to the conditions and limitations as described herein.  
c. Attachments marketed through or approved by Dixon Industries, Inc. are warranted for one year  
parts and labor in commercial use applications.  
d. Pro Series Models are not subject to hour meter restrictions.  
e. Warranty applies to new and unused mowers and is transferable.  
2. RESIDENTIAL WARRANTY (used only at owner’s primary place of residence):  
a. Three years - 100% parts and labor subject to the conditions and limitations described herein for  
a period of three years from date of purchase by the original owner.  
b. Attachments marketed through or approved by Dixon Industries, Inc., are warranted for two  
years parts and labor in residential use applications.  
c. 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 published Dixon® flat rate schedule.  
6. Warranty does not apply to damage in transit or incidents of misuse, negligence, accidents,  
or alteration. The use of parts or components other than those supplied by Dixon Industries  
VOIDS ALL WARRANTY.  
7. Battery warranty is limited to one year from date of manufacture.  
8. The following items are not covered by this warranty policy:  
(a) Routine maintenance or adjustments to include any oils, filters or other fluids used.  
(b) Belts, blades, tires and cosmetic appearance (paint, seat fade, etc.)  
(c) Pick up and delivery charges for transportation of mower to and from an authorized  
Dixon® dealer’s place of business.  
(d) Engines. These are covered under a separate warranty by each individual engine  
manufacturer. Consult engine manual for warranty details.  
(e) Any costs or expense of providing substitute equipment while repair work is being  
performed on a warranted mower.  
9. THERE IS NO OTHER EXPRESS WARRANTY. TO THE EXTENT PERMITTED BY LAW, ALL  
IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A  
PARTICULAR PURPOSE ARE EXCLUDED; OTHERWISE, ALL SUCH IMPLIED WARRANTIES ARE  
LIMITED TO THE SAME DURATION AND REMEDIES AS THE EXPRESS WARRANTY. ALL  
LIABILITIES FOR CONSEQUENTIAL DAMAGES UNDER ANY EXPRESS OR IMPLIED WARRANTY  
ARE EXCLUDED.  
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SPECIFICATIONS  
KODIAK®  
CHASSIS:  
SEAT:  
11 GA - rectangular tube  
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. Mounted on operator suspension system.  
MOWER DECK:  
Made of 11 GA fabricated welded construction with external  
reinforcement ribs. Three blades combine for a 52” or 60”  
cut width. Cut height approximately 1.5” to 5” via 12  
position lift handle.  
BLADE DRIVE:  
DRIVE SYSTEM:  
Electric clutch  
Each rear wheel is independently driven by a Parker 10cc  
pump and TJ0230 wheel motor.  
ENGINE:  
Each mower is powered with either a 21HP Kawasaki,  
20 HP Honda, 20 HP or 25 HP Kohler, 26 HP Briggs &  
Stratton ELS twin cylinder 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 blade drive clutch.  
TIRES:  
Front 13 x 5 x 6 smooth tread (15 lbs)  
Rear 23 X 9.5 - 12 (15 lbs)(52” decks) or  
23 X 10.5 - 12 (15 lbs)(60” decks)  
CAPACITIES:  
DIMENSIONS:  
(approximate)  
Fuel - 11 gallon (approximately)  
Hydrostat Oil tank - 4 quart with in-line 25 micron filter  
Engine - 2 qts. SAE 10W30 (with filter)  
Width  
48” outside rear wheel measurement (52”  
decks)  
52” outside rear wheel measurement (60”  
decks)  
Height  
Length  
Weight  
70.5” ROPS up, 57” ROPS down  
79” (52” decks), 81” (60” decks)  
960 lbs. (52” decks)  
990 lbs. (60” decks)  
Additional information may be provided elsewhere in this manual.  
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE  
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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.  
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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 for-  
ward.  
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.  
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 direction opposite  
of travel.  
LEFT TURN OPPOSITE  
Note: The pressure required to operate the mower is very light.  
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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.  
Engage parking brake  
CAUTION  
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.  
MOWER DECK CUT HEIGHT LIFT LEVER:  
Located to the right and front of the operator.  
Controls the cutting height.  
Fifteen positions of adjustment  
Depress trigger and move lever forward to lower deck.  
Depress trigger and pull lever back to raise deck.  
Note: Always use high position for transport.  
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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.  
CHOKE AND THROTTLE CONTROL LEVERS:  
•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  
and to maintain mower deck blade speed while  
mowing.  
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OPERATION INSTRUCTIONS  
The safe and successful operation of the KODIAK™  
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.  
NEVER 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 sure it is in place.  
5. Be sure parking brake is on.  
6. Be sure mower blade drive is off.  
7. Know how to stop engine. (Turn key to off position).  
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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 1/2 speed setting. If engine is cold, position  
choke lever to the “on” 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. 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.  
CAUTION Do not operate the engine in an enclosed area  
due to the harmful exhaust gas produced.  
Note:  
Engage blade drive with throttle in the mid-range  
position. When mowing (blades engaged), set  
throttle control to the MAXIMUM or wide open setting  
to ensure adequate cooling of the engine and to  
maintain mower deck blade speed.  
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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.  
CONTROL LEVER SWITCH TEST:  
a) Disengage blade drive 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.  
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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.  
SEAT SWITCH TEST:  
a) In 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.  
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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. Set 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  
cuttings or if the lawn is heavily fertilized.  
5. Do not attempt to cut grass when it is wet. Mulching  
performance will be very poor in wet grass conditions.  
6. Maintain sharp blades throughout the cutting season.  
This is very important. Optimal mulching performance  
cannot be obtained with a dull or nicked up blade.  
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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 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.  
d. Overlap cutting swaths instead of cutting  
a full swath with each pass.  
e. Mow across the marginal areas a second  
time.  
f. CUT HIGH - MOW OFTEN!  
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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. 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 circumstances, should you place hands  
or feet under the mower deck or in the chute  
while blades or impeller are still turning.  
6. Operate the mower at a slower ground speed than  
when mowing without a grass catching attachment.  
28  
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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. Some mowing applications/use of grass catchers  
may require that 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  
regarding installation and adding weight to the box.  
Failure to observe the following instructions  
may result in personal injury.  
WARNING  
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 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. Operator or bystanders could be injured by  
thrown objects.  
•Keep all attachment bolts tight.  
Important: Do Not leave clippings in the bags while the mower is  
stored. Damp grass clippings are a fire hazard if left in the bag.  
29  
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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. 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  
the clippings to discharge correctly. 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.  
5. Maintain sharp blade(s) throughout the cutting  
season.  
30  
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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. 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 local lawn professional for assistance.  
Grass Types  
Bermudagrass  
Bluegrass  
Buffalograss  
Ryegrass  
Best Cut Heights  
1 - 2”  
2 - 3”  
11/2 -3”  
2 - 3”  
3-31/2”  
Tall Fescue  
Zoysiagrass  
1 - 3”  
31  
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OPERATION INSTRUCTIONS  
TOWING TRAILERS AND OTHER ATTACHMENTS:  
Towing a trailer or other attachment is not recommended.  
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.  
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 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 towing tractor, transmission must be  
unlocked and parking brake released. The tractor  
should never be pulled at more than 2 miles per hour or  
for any appreciable distance.  
32  
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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 belt.................................................after 20 hours break-in  
Check crankcase oil level.............................................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 50 hours  
Check all belts...............................................................every 50 hours  
Change engine crankcase oil & filter.....(5 hours break-in)every 50 hours  
Change engine oil filter...................................................every 50 hours  
Replace air filter element.............................annually or every 100 hours  
Replace spark plugs.....................................................every 100 hours  
Change hydrostat oil & oil filter..........(100 hours break-in)every 500 hours  
33  
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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. Be sure blade is  
centered on pilot before  
tightening to 60 ft. lbs.  
Blades should be discarded when worn excessively.  
DANGEROUS!  
DO NOT USE  
BLADE IN THIS  
CONDITION!  
New Blade  
When notch starts,  
discard blade  
34  
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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.  
Battery contains sulfuric acid electrolyte which  
is poisonous and corrosive.  
CAUTION  
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.  
•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 charge levels during periods of inactivity and  
may prevent premature battery failures. Contact your  
dealer for more information.  
35  
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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  
15 lbs.  
15 lbs.  
Lug nuts or lug bolts should be checked regularly for tightness.  
LUBRICATION:  
CHASSIS:  
(11) grease zerks  
LOCATIONS:  
deck lift (1)  
pump idler arm (1)  
front wheel casters (4)  
mower deck hubs (3)  
drive controls (2)  
SERVICE INTERVALS:  
Every 50 hours of operation or  
once per season.  
RECOMMENDED  
GREASE:  
Name brand wheel bearing  
or multi-purpose grease  
(3 pumps each)  
36  
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CARE AND MAINTENANCE  
BELTS:  
Check belts every 50 hours. Replace any belts found to be  
in poor condition.  
37  
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CARE AND MAINTENANCE  
HOT oil may cause burns. Allow  
engine to cool before draining oil.  
CAUTION  
CHANGING THE ENGINE OIL:  
1. The 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. Change oil filter.  
6. Fill with oil (see steps on next page).  
NOTE:  
Refer to engine manufacturer’s recommenda-  
tions for frequency of oil changes.  
Hex Head Valve  
Stem  
38  
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CARE AND MAINTENANCE  
HOT oil may cause burns. Allow  
engine to cool before draining oil.  
CAUTION  
OIL FILL:  
1. Clean any spilled oil from engine and chassis.  
2. Refill engine with type, and quantity of oil recom-  
mended by the engine manufacturer in engine  
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 oil is changed.  
2. Oil Filters can be obtained from your authorized  
engine dealer.  
3. The use of any other oil filter may cause damage to  
the engine.  
PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS.  
PROTECT YOUR ENVIRONMENT.  
39  
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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 -  
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.  
FLUID FILTER: P/N 539 102606 - IMPORTANT  
The fluid filter is a special design for use on  
“vacuum or suction” oil flow systems.  
DO NOT:  
Use automotive engine oil filters. These  
filters require a “pressure” to allow oil flow.  
Usage will result in an “air-lock” condition  
with possible damage.  
40  
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CARE AND MAINTENANCE  
HYDROSTAT FLUID MAINTENANCE  
PROCEDURE:  
Check the fluid level in hydrostatic transmission fluid  
reservoir after every 25 hours of usage. Clean the fluid  
reservoir cap and the area around it prior to removal.  
Check the fluid level. Fluid should be approximately  
1/4” below top of fluid tank baffle. Replenish as needed  
with 15W-50 Synthetic Hydrostatic Fluid. DO NOT  
OVERFILL. When checking the fluid level, be very  
careful to keep the reservoir clean.  
Change the fluid in the reservoir and hydrostatic  
transmission fluid filter after the first 100 hours of use,  
then every 500 hours after that. Remove the filter and  
be sure all fluid has drained from the reservoir. Replace  
with a new OEM filter (P/N 539 102606) and 15W-50  
Synthetic Hydrostatic Fluid.  
DO NOT USE OR ADD STANDARD (RED) HYDRAULIC/  
TRANSMISSION OIL IN YOUR DIXON HYDROSTATIC  
DRIVE. DAMAGE TO THE DRIVE COMPONENTS MAY  
OCCUR. USE ONLY APPROVED 15W-50 SYNTHETIC  
HYDROSTATIC FLUID OR 20W-50 TYPE ENGINE OIL.  
41  
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CARE AND MAINTENANCE  
NEUTRAL ADJUSTMENT  
1. Lift seat.  
2. Blockuptheunitsothatthedrivewheelsareoff the  
ground.  
3. Loosen ball joint jam nuts on control rod.  
Note: Thefront jamnutsarelefthandthreads.  
4. With steering control arms in the “out” neutral  
position, start the engine and run at fast idle.  
5. Adjusttheneutralpositionbyturningthecontrolrod  
untilthewheelsdonotrotate.  
6. Re-tighten the jam nuts on the control rod and  
checktoseethatthedrivewheelsarenotturning.  
7. Repeat steps 3-6 for the other side.  
8. Shut off engine before removing the blocks.  
42  
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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. 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.  
PARTS/SERVICE:  
See your Dixon® dealer for replacement parts, warranty  
or service.  
43  
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CARE AND MAINTENANCE  
MOWER DECK LEVELING PROCEDURE:  
Before performing any service or adjustment check list:  
1. Engage parking brake.  
2. Place blade-switch in the disengaged position.  
3. Turn ignition switch to “OFF” position and remove  
key.  
4. Make sure blades and all moving parts have com-  
pletely stopped.  
5. Disconnect spark plug wire from all spark plugs and  
place wire where it cannot come in contact with plug.  
Blades are sharp. Protect your hands with  
gloves and/or wrap blades with a heavy cloth  
when handling.  
1. Position the mower on a level, hard surface  
2. Check the pressure in all four tires. See “Technical Data”  
section in this manual.  
3. Set deck cutting height at 4".  
4. Rotate blades to align front to back.  
5. Measure front blade tip, should be 4” from ground, if not  
turn locknut on top of front eyebolt till measurement is  
achieved. Check blade tip at front on opposite front blade.  
Adjust locknut on front eyebolt as necessary.  
44  
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CARE AND MAINTENANCE  
MOWER DECK LEVELING PROCEDURE  
(continued):  
6. Check rear blade measurement, should be 4 1/4” from  
ground, if not turn locknut on top of rear eyelbolt to  
achieve measurement. Repeat procedure on opposite  
side.  
8. If deck leveling cannot be achieved call Technical  
Support at toll free number 1-877-288-6673.  
3
2
1
4
1. Front eyebolt  
2. Front locknut  
3. Rear locknut  
4. Rear eyebolt  
Leveling mower deck  
45  
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TROUBLESHOOTING  
1. ENGINE WON’T TURN OVER  
Mower blades engaged- - - - - - - - - - - - - - - - - - - disengage blades  
Parking brake not on- - - - - - - - - - - - - - - - - - engage parking brake  
Circuit breaker trips- - - - - - - - - - - - - - - - - - - - - - - - -reset breaker  
Dead battery- - - - - - - - - - - - - - - - - - - - - - - - - - charge or replace  
Solenoid- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Ignition switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Starter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
2. ENGINE WILL TURN OVER BUT WON’T START  
No fuel- - - - - - - - - - - - - - - refuel and/or 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 screen and fins  
Oil level too low or too high- - - - - - - - - - - - - - - - - - - -adjust oil level  
Running engine too slow - - - - - - - - - - - - - - - - - -run engine faster  
46  
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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- - - - - - - - - - - - -disengaged  
7. MOWER LOSES POWER ORTRANSMISSION OVERHEATS  
Engine air filter-- - - - - - - - - - - - - - - - - - - - - - - - - - clean or replace  
Transmission damage- - - - - - - - - - - - - - - - - - - - - - -consult dealer  
8. ENGINE STALLS WHEN BLADES ARE ENGAGED  
Operator not on seat- - - - - - - - - - - - - - - - - - - - - - - - - -sit on seat  
Faulty interlock system- - - - - - - - - - - - - - - - - - - - - - consult dealer  
Faulty 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 right- - - - - - - - - - - -check tire inflation/level deck  
Ends of grass blades are ragged- - - - - - - - - - - - - - sharpen blades  
Poor dispersal of grass- - - - - - - - - - clean deck/check for loose belt  
Skips in spots- - - - - - - - - - -check for loose belt/slow ground speed  
47  
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STANDARD SERVICE PARTS LIST  
52"  
Blades  
*Hi-Lift - P/N 539 117911  
*Factory installed  
Belts  
Engine to Mower Deck - P/N 539 114557  
Engine to Hydros - P/N 539 106887  
60"  
Blades  
*Hi-Lift - P/N 539 119840  
*Factory installed  
Belts  
Engine to Mower Deck - P/N 539 114508  
Engine to Hydros - P/N 539 106887  
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. Refer to the Engine Operator’s Manual or ask your dealer  
for correct replacement parts.  
48  
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OWNER’S INFORMATION  
Date of Purchase  
Mower Model Number  
Mower Serial Number  
Purchased From  
Name  
Address  
DATE OIL CHANGED  
DATE ENGINE TUNED  
Dixon~401 N. Commerce St. Beatrice, NE 68310  
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Dixon® and ZTR® are registered trademarks of Dixon  
The engine exhaust from this product contains  
WARNING: chemicals known to the State of California to cause  
cancer, birth defects or other reproductive harm.  
DIXON  
401 N. Commerce St..  
Beatrice, NE 68310  
KODIAK®  
Part No. 114518Rir - 11/07/06  
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