Dixon Kodiak Diesel Operation and maintenance manual

Safety Instructions
&
Operator’s Manual
KODIAK
®
DIESEL ZTR
®

2
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.
The information contained in this manual
applies to all Dixon® Kodiak® Diesel ZTR®
mowers.
See your authorized Dixon® dealer for
warranty service, parts and repairs or to
answer any questions you may have about
your new Dixon® ZTR®.

3
TABLE OF CONTENTS
Page
SAFETY & WARNING....................................4-15
WARRANTY........................................................16
SPECIFICATIONS.............................................17
SEAT ADJUSTMENT.........................................18
CONTROLS..................................................19-21
OPERATION INSTRUCTIONS....................22-32
CARE & MAINTENANCE............................33-46
TROUBLESHOOTING..................................47-48
STANDARD SERVICE PARTS LIST...............49
KODIAK® DIESEL
Part Number 18626-106

SAFETY
4
Blade Contact
Tip Over
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.

SAFETY
5
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.

WARNING
6
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.

WARNING
7
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.
Failure to observe the following safety instructions
could result in serious injury or death.

WARNING
8
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.
GENERAL OPERATION (continued):
The engine exhaust from this product contains chemicals known to the State of
California to cause cancer, birth defects or other reproductive harm.
Failure to observe the following safety instructions
could result in serious injury or death.

WARNING
9
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.
Failure to observe the following safety instructions
could result in serious injury or death.

WARNING
10
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.
SLOPE OPERATION (continued):
DO (continued):
Failure to observe the following safety instructions
could result in serious injury or death.

WARNING
11
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.
Failure to observe the following safety instructions
could result in serious injury or death.

WARNING
12
FIRE HAZARDS:
Use extra care when handling diesel 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 diesel 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.
Failure to observe the following safety instructions
could result in serious injury or death.

WARNING
13
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.
Failure to observe the following safety instructions
could result in serious injury or death.

WARNING
14
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.
Failure to observe the following safety instructions
could result in serious injury or death.

WARNING
15
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.
Never loosen the radiator cap if the engine is hot.
Failure to observe the following safety instructions
could result in serious injury or death.

16
DIXON® ZTR® PRO SERIES COMMERCIAL/RESIDENTIAL WARRANTY POLICY
Black BearTM, Kodiak®, Mountain Kodiak®, 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.

SPECIFICATIONS
17
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
Additional information may be provided elsewhere in this manual.
KODIAK® DIESEL
CHASSIS: 11 GA - rectangular tube
SEAT: 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 and 7 GA fabricated welded construction with
multiple 1/4” and 3/8” reinforcement ribs. Three blades
combine for a 52” cut width. Cut height approximately 1.5” to
5” via 18 position lift handle with foot assist.
BLADE DRIVE: Electric clutch
DRIVE SYSTEM: Each rear wheel is independently driven by a HydroGear
12cc pump with fans and TJ230 wheel motor.
ENGINE: The mower is powered by a 20 HP Yanmar Diesel twin
cylinder engine, overhead valve, liquid cooled, 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 6.5 x 6 smooth tread (16-21 lbs)
Rear 23 X 10 X 10 Turf Master (8-14 lbs)
CAPACITIES: Fuel - 11 gallon (approximately)
Hydrostat Oil tank - 4 quart with in-line 25 micron filter &
Dixon BlueTM 15w50 Synthetic Hydrostatic Fluid
Engine - 2 qts. SAE 10W30 (with filter)
Radiator - 50/50 mix
DIMENSIONS: Width 47” outside rear wheel measurement
(approximate) Height 46.5”
Length 79” hitch tab to front
Weight 1135 lbs.

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.

CONTROLS
19
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.
Note: The pressure required to operate the mower is very light.
LEFT TURN OPPOSITE

CONTROLS
20
CAUTION
MOWER DECK CUT HEIGHT LIFT LEVER:
•Located to the right and front of the operator.
•Controls the cutting height.
•Eighteen positions of adjustment
•Push foot lever forward, depress trigger and move lever
forward to lower deck.
•Push foot lever forward, depress trigger and pull lever
back to raise deck.
Note: Always use high position for transport.
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
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.