™ BLACK BEAR ™ BLACK BEAR ® ZTR ZTR® Safety Instructions and Operator’s Manual Models ZTR®34/968999564 ZTR®44/968999565 ZTR®34/968999566
IMPORTANT - READ CAREFULLY The Dixon® ZTR® mower is both easy and fun to operate. However, any power mower must be operated properly to be safe. It is not a toy or a recreational vehicle. Before you start to use the mower, read 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.
TABLE OF CONTENTS SAFETY AND WARNINGS ............................................................ 4-15 GENERAL OPERATION ................................................... 6-7 MOWING ON A SLOPE .................................................... 8-9 FIRE HAZARDS ............................................................ 10-11 CHILDREN, BYSTANDERS AND PETS ............................ 12 SERVICE ............................................................................ 13 WARRANTY ....................
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.
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.
WARNING ! WARNING Failure to observe the following 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 bystanders before mowing.
WARNING ! WARNING Failure to observe the following instructions could result in serious injury or death. GENERAL OPERATION (continued) 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 engagement, stop engine before removing grass catcher or unclogging chute.
WARNING ! WARNING Failure to observe the following 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 unsure on any 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.
WARNING ! WARNING Failure to observe the following 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 embankments. Unstable ground may cause loss of control. 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.
WARNING ! WARNING Failure to observe the following 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.
WARNING ! WARNING Failure to observe the following 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.
WARNING ! WARNING Failure to observe the following instructions could result in serious injury or death. CHILDREN, BYSTANDERS AND PETS Tragic accidents can occur if the operator is not alert to the presence of children, bystanders and pets. Children are attracted to lawn mowers and the mowing activity. NEVER assume children, bystanders and pets will stay where they were last seen. Be alert to avoid accidents.
WARNING ! WARNING Failure to observe the following 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.
DIXON® ZTR® PRO SERIES COMMERCIAL/RESIDENTIAL WARRANTY POLICY Black Bear™, Kodiak™, 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.
SPECIFICATIONS BLACK BEAR™ 34 Model 968999564 Chassis: Body: Mower Deck: Blade Drive: Drive System: Engine: Starting System: Tires: 11 gauge 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. Made of 7 gauge fabricated welded construction with external reinforcement ribs. Two blades combine for a 34" (86cm) cut width.
SPECIFICATIONS BLACK BEAR™ 34 Model 968999566 Chassis: Body: Mower Deck: Blade Drive: Drive System: Engine: Starting System: Tires: 11 gauge 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. Made of 7 gauge fabricated welded construction with external reinforcement ribs. Two blades combine for a 34" (86cm) cut width.
SPECIFICATIONS BLACK BEAR™ 44 Model 968999565 Chassis: Body: Mower Deck: Blade Drive: Drive System: Engine: Starting System: Tires: 11 gauge 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. Made of 7 gauge fabricated welded construction with external reinforcement ribs. Three blades combine for a 44" (112cm) cut width.
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 —Fig.
CONTROLS CONTROL LEVERS For access to the seat, move control levers to neutral position and swing them outward. NEUTRAL SLOW FORWARD FAST FORWARD —Fig. 2— 90o RIGHT SLOW REVERSE TURN Left Turn Opposite TO GO FORWARD • From neutral position, gently push control levers forward. • To increase speed, move levers further forward. TO GO BACKWARDS • From neutral position, gently pull control levers toward you.
CONTROLS PARK BRAKE The park 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 park brake is engaged while the control levers are in the drive position. ! CAUTION Engage park brake before starting engine. TO SET PARK BRAKE The hand-operated park brake is located on the operator’s left. —Fig. 3— •To engage brake, pull lever up (to the rear). •To release brake, move lever forward (down).
CONTROLS MOWER DECK CUT HEIGHT LIFT LEVER • Located to the right and front of the operator. Trigger • Controls the cutting height. • 17 positions of adjustment Pin • Depress trigger and move Each hole provides lever forward to lower deck. a different cut • Pull lever back to raise deck. height adjustment • Set desired cut height with Foot Pedal pin. —Fig. 4— • Use foot pedal to assist with raising and lowering deck. NOTE: Always use high position for transport.
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. CIRCUIT BREAKER • • • • Located on the control panel to the operator’s right. Protection of the electrical 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. —Fig.
OPERATION INSTRUCTIONS The safe and successful operation of the SpeedZTR will depend on 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 who does not have complete knowledge of all controls and their functions to operate the mower. NEVER dismount mower without applying park brake or stopping engine. During initial operation, “learning to drive”, set throttle at slow speed.
OPERATION INSTRUCTIONS ! CAUTION Failure to observe the following instructions could result in personal injury. STARTING INSTRUCTIONS 1. Park brake must be on, control levers in outward position and blade drive disengaged. 2. Position throttle to choke position if engine is cold. Full throttle if warm. 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.
OPERATION INSTRUCTIONS TESTING OF SAFETY INTERLOCK SYSTEMS ! WARNING Failure to observe the following instructions could result in serious injury or death. The following tests should be performed at the start of each mowing day. PARK BRAKE SWITCH TEST 1. Swing control levers to outward position. 2. Disengage blade drive. 3. Put park brake in OFF position. 4. Turn ignition switch to START. Engine should not turn over or attempt to start. CONTROL LEVER SWITCH TEST 1. Disengage blade drive. 2.
OPERATION INSTRUCTIONS TESTING OF SAFETY INTERLOCK SYSTEMS ! WARNING Failure to observe the following 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 1. Put park brake in ON position. 2. Swing control levers to outward position. 3. Engage blade drive. 4. Turn ignition switch to START. Engine should not turn over or attempt to start. SEAT SWITCH TEST 1. In a safe area away from bystanders, start engine.
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.
OPERATION INSTRUCTIONS MOWING WITH A MULCHING ATTACHMENT (continued) 7. Keep the underside of the mower deck clean. Remove all grass and dirt buildup from the underside of the pan, the baffles and deflectors after each use. Never, under any circumstances, place your hands or feet under the mower deck or in the chute while blades or impeller are still turning. 8. Alternate mower direction. This will evenly disperse the mulched grass clippings over the lawn for even fertilization.
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.
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 or the 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.
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 on Page 47-48. ! 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.
OPERATION INSTRUCTIONS GRASS HEIGHT AND 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 one third of the total grass blade length.
OPERATION INSTRUCTIONS TOWING TRAILERS AND OTHER ATTACHMENTS Towing a trailer or other attachment that is too heavy could damage the drive or cause the mower to become unstable. Limit loads to 250 pounds (113 kg) or less with this mower. 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.
CARE AND MAINTENANCE ! WARNING Failure to observe the following instructions could result in personal injury. Before performing any maintenance, turn off engine, allow to cool and 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 serpentine belt ..................
CARE AND 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. CUTTER BLADE MAINTENANCE Check sharpness of mower blades after every 10 hours of operation. Observe proper blade position prior to removal. Spindle Assembly 1. Safely raise front of mower. 2. Hold or block blade from turning. Mower Blade 3. Loosen blade bolt and remove blade. 4. When replacing blade, tighten blade bolt securely.
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. ! CAUTION Battery contains sulfuric acid electrolyte that is poisonous and corrosive. 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.
CARE AND MAINTENANCE BELTS Check belts every 50 hours. Replace any belts showing signs of wear or cracking. BELT TENSION Engine to Mower Deck Belt: 34" P/N 539 117811 44" P/N 539 118156 Manual adjustment. Turn nut on deck eyebolt to adjust belt tension. Turn nut to adjust belt tension —Fig. 11— NOTE: Belt deflection or movement should be approximately ¼"(6mm) when measured at midpoint between pulleys. Periodically inspect both belt and idler systems.
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 13 x 5 - 6 16-21 PSI (110-145 kPa) Rear tires 23 x 8.5 - 12 8-14 PSI (55-97 kPa) Lug nuts or lug bolts should be checked regularly for tightness.
CARE AND MAINTENANCE ! CAUTION HOT oil may cause burns. Allow engine to cool before draining oil. CHANGING THE ENGINE OIL 1. The “Dapco” 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). Hex Head Valve Stem —Fig. 12— 4.
CARE AND MAINTENANCE HYDROSTATIC TRANSMISSION OIL AND FILTER SERVICE Dirt or water in oil can ruin the hydrostatic transmissions. SERVICE INTERVALS • Initial filter service - 100 hours • Every 500 hours or once a year thereafter. RECOMMENDED Oil All temperatures 15W-50 Synthetic Hydrostatic Oil ~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.
CARE AND MAINTENANCE HYDROSTAT OIL MAINTENANCE PROCEDURE Check the oil level in hydrostatic transmission oil reservoir after every 25 hours of usage. Clean the oil reservoir cap and the area around it prior to removal. Check the oil level. Oil should be approximately ¼” below top of oil tank baffle. Replenish as needed with 15W-50 Synthetic Hydrostatic Oil or a quality SAE 20W-50 motor oil. DO NOT OVERFILL. When checking the oil level, be very careful to keep the reservoir clean.
CARE AND MAINTENANCE NEUTRAL ADJUSTMENT 1. Lift seat. 2. Block up the unit so that the drive wheels are off the ground. Remove rear tires. 3. Loosen jam nuts on both ends of the control rod coupler. NOTE: The rear jam nuts are left hand threads. 4. With steering control arms in the outward (neutral) position, start the engine and run at fast idle. 5. Adjust the neutral position by turning the control rod coupler until the hubs do not rotate. 6.
CARE AND MAINTENANCE MOWER DECK LEVELING PROCEDURE There are four(4) slots that will control the attitude or pitch of the mower deck. The deck should be level or pitched slightly higher in rear. 1. Place the mower on a smooth level surface with front casters positioned towards deck. Check tire pressures to insure the mower has a correct stance.
CARE AND MAINTENANCE MOWER DECK LEVELING PROCEDURE (continued) 4. Turn both outer blades to align with the deck in front-torear manner. Reposition rear mounting bolts up or down until rear of mower deck is positioned level to 1/8" higher in the rear than the side-to-side measurement. 5. Confirm measurements once again. Blade tips should be level in a side-to-side manner. In the rear, blade tips should be level to 1/8" higher than side-to-side measurement.
CARE AND MAINTENANCE MOWER DECK REMOVAL 1. Remove mower deck drive belt from clutch. To relieve belt tension, loosen nut on tensioner 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 arms to rear of deck. 5. Slide deck from beneath chassis. 6. Reverse procedure to reinstall deck to chassis.
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.
TROUBLESHOOTING 1.
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 bypass may be engaged - - - disengage (see page 23) 7.
STANDARD SERVICE PARTS LIST BLADES AND BELTS 34" Deck Blade * Hi-Lift Fusion Standard Lift Fusion Gator Fusion P/N 539 118039 P/N 539 117766 P/N 539 117767 Transmission Belt Deck Belt P/N 539 118012 P/N 539 117811 44" Deck Blade * Hi Lift Fusion Standard Lift Fusion Gator Fusion P/N 539 117843 P/N 539 117842 P/N 539 117841 Transmission Belt Deck Belt P/N 539 118012 P/N 539 118156 *Factory installed ENGINE AIR AND OIL FILTERS Refer to Engine Operator’s Manual for correct service intervals for engine
OWNER’S INFORMATION Date of Purchase ________________________________ Mower Model Number _____________________________ Mower Serial Number _____________________________ Purchased From ________________________________ ________________________________ ________________________________ DATE OIL CHANGED DATE ENGINE TUNED ____________________ _____________________ ____________________ _____________________ ____________________ _____________________ ____________________ _____________________ ___________
Dixon and ZTR® are registered trademarks of Dixon ! WARNING DIXON 401 Commerce Street Beatrice, NE 68310 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. SpeedZTR Black Bear Part No.
