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Dixon ZTR 5000 Series Operator's Manual

Dixon lawn mower operator's manual
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  • Page 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 the operator's manual carefully and become completely familiar with the controls.

  • Page 3: Table Of Contents

    SAFETY ..WARRANTY POLICY ... SPECIFICATIONS ... SEAT ADJUSTMENT ... CONTROLS ... OPERATION INSTRUCTIONS ... CARE AND MAINTENANCE ... STANDARD SERVICE PARTS LIST ... TROUBLESHOOTING ... Part No. 8965 5/98 INDEX Pages Page Page Page Pages 11-14 Pages 15- Pages 23- ...

  • Page 4: Safety

    SAFETY RIDING LAWNMOWERS, IF IMPROPERLY OPERATED, CAN CAUSE SERIOUS INJURY OR DEATH The most common causes of injury to the operator or bystander..read and understand this manual to prevent injuries. Page 2...
  • Page 5 SAFETY SAFETY ALERT SYMBOL - When you see this symbol, BE ALERT to the potential for injury. Follow recommended safety precautions and safe operating practices. Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Warning indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

  • Page 6: General Operation

    This cutting mower is capable of amputating hands and feet, and throwing objects. Failure to observe the following safety instructions could result in GENERAL OPERATION: • Read, understand, and follow all instructions in the manual and on the mower before starting. •...

  • Page 7: Slope Operation

    If you cannot back up the slope or if you feel uneasy on it, do not mow it. Mow across the slope with your Dixon ZTR - never up or down. Remove obstacles such as rocks, tree limbs, etc.
  • Page 8 CHILDREN: Tragic accidents can occur if the operator is not alert to the Children are attracted to lawn mowers and the mowing activity. NEVER assume children will stay where they were last seen. • Keep children out of the mowing area and under the watchful care of another responsible adult. •...
  • Page 9 SERVICE: • Use extra care in handling gasoline and other fuels. They are flammable and vapors are explosive. Use only an approved container. Never remove gas cap or add fuel with the engine running. Allow engine to cool before refueling. Do not smoke. Never refuel the mower indoors.

  • Page 10: Warranty Policy

    This warranty policy applies to all HydroGear mowers or any 50" model, purchased on or after March 1,1990. WARRANTY: Dixon Warranty term is for a period of one (1) year from date of purchase or 400 hours of use, whichever occurs first.

  • Page 11: Specifications

    CHASSIS: 11 GA - rectangular tube BODY: Two piece - made of high-density polyethylene. Front body contains access panels for battery service and engine to mower deck belt removal. Rear body tilts up to allow service on the entire drive system. SEAT: Economically designed for operator comfort, contoured back rest and arm rests.

  • Page 12: Seat Adjustment Instructions

    SEAT ADJUSTMENT INSTRUCTIONS Model ZTR 5022: Set parking brake. Raise upper body. Loosen two front seat adjustment knobs and slide seat forward or backward tc desired position. Re-tighten front seat adjustment knobs. DO NOT operate mower without seat adjustments properly tightened. Carefully lower upper body and seat assembly to the closed position.

  • Page 13: Controls

    Page 11 CONTROLS 5000 Series...
  • Page 14 PARKING BRAKE: The parking brake used on the 5000 Series Models is designed to hold the mower from moving and is not intended for use in stopping the mower while it is in motion. Engage parking brake before starting CAUTION engine Do not leave engine running for extended periods of time without the parking brake engaged.
  • Page 15 TO GO FORWARD: From neutral position, gently push both drive levers forward. To increase speed, move levers farther forward. TO GO BACKWARD: From neutral position, gently pull both drive levers toward you. TURNING: Turning is controlled by moving one drive lever slightly forward or rearward of the other. To turn left, move left lever rearward of the right lever.

  • Page 16: Controls

    BLADE DRIVE: Located on control panel, on operator's right. 1998 Models To engage blades: Slide switch to rear and flip up and forward. To disengage blades: Flip switch down. 1999 Models To engage blades: Pull switch up. To disengage blades: Push switch down. CIRCUIT BREAKER: Located on control panel, on operator's right.

  • Page 17: Operation Instructions

    OPERATION INSTRUCTIONS The safe and successful operation of the 5000 Series Models 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.
  • Page 18 ON position. Raise weight slightly off of seat. Engine should stop. c. If any Safety Check fails, do not operate the mower until the system has been checked and repaired by an Authorized Dixon ZTR Dealer.
  • Page 19 OPERATION INSTRUCTIONS STARTING INSTRUCTIONS: 1. Position choke control in ON position. 2. Position throttle control at 1/2 speed setting. 3. Insert ignition key and turn to "Start" position. When engine starts, release ignition key. Key will return to "Run" position. 4.
  • Page 20 OPERATION INSTRUCTIONS STARTING INSTRUCTIONS: 1. Move throttle control to 1/4 to 1/2 setting. 2. Insert ignition key and turn to "Start" position. When engine starts, release ignition key. Key will return to "Run" position. 3. Move throttle control to FAST position for actual operation of the mower deck.
  • Page 21 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 of the recycled or mulched clippings. In order to achieve the best results, please read and follow the mulching tips listed below: Set the engine speed control to the wide open or full setting.
  • Page 22 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: Set engine speed control to the wide open or full setting. Do Not Attempt To Cut Grass When It Is Wet.
  • Page 23 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 40. Be sure that deflector is properly installed on the dischargechute.
  • Page 24 OPERATION INSTRUCTIONS DECK ROLLERS: The spring loaded deck rollers located at the front corners of the 60" mower deck Purpose: are designed as an aid to limit turf scalping when mowing on uneven ground. Normal height settings as installed at the factory allows each roller to ride slightly Height: above the turf.

  • Page 25: Care And Maintenance

    Please remember that if you are in doubt as to the correct service procedures to be followed, these and other service situations can be handled by a Dixon ZTR dealer who is familiar with the service of your mower.
  • Page 26 CARE AND MAINTENANCE MOWER BLADE MAINTENANCE: NOTE: Observe proper blade position prior to removal. 1. Safely raise front of mower. 2. Hold or block blade from turning. 3. Loosen blade nut and remove blade. 4. Tighten blade nut securely. Refer to diagram. NOTE: Be sure blade is centered on pilot before tightening bolt to 60 ft.
  • Page 27 CARE AND MAINTENANCE ENGINE TO MOWER DECK BELT: 42' and 50" 60" The engine to mower deck drive belts are automatically held in proper tension by springs which push the deck assembly forward and do not require any additional adjustment to be made.
  • Page 28 CARE AND MAINTENANCE FUEL SHUT OFF VALVE: A fuel shut off valve is located at the bottom rear of each fuel tank. Always turn the valve to the "OFF" position when the mower is stored or not in use. LUBRICATION CHASSIS: LOCATIONS: SERVICE INTERVALS:...
  • Page 29 CARE AND MAINTENANCE 5000 SERIES REAR WHEELS: The rear wheels of all 5000 Series models are of an "offset" center design to allow "reversed" installation for using snow chains or to gain increased stability when mowing on sloped ground. Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death.
  • Page 30 CARE AND MAINTENANCE CHANGING THE ENGINE OIL: 1. The "snap lock" oil drain valve is located on the left side of the engine crankcase. 2. Place a suitable container under the drain valve. The short piece of hose will help direct the oil. 3.
  • Page 31 CARE AND MAINTENANCE MOWER DECK REMOVAL: 1. Remove mower deck drive belt. To relieve belt tension, insert 5283 link (at front of lift frame) into tab illustrated below. Move lift handle into the lowest cut positon. Belt can now be removed from mower deck pulley. 2.
  • Page 32 CARE AND MAINTENANCE MOWER DECK LEVELING PROCEDURE: There are a total of (4) threaded adjusters which will control the attitude or pitch of the mower deck. The adjusters have lock nuts on the bottom which can be turned up or down to raise or lower the front and rear of the mower deck.
  • Page 33 CARE AND MAINTENANCE Adjustment of the drive system is limited to the actual function of the hydrostatic transmissions as outlined below. T-BOX TO HYDROSTAT BELT ADJUSTMENT: Tighten the (2) J-bolts on the T-box mounting plate until each belt has 1/8th to 1/4th of an inch free play or movement at a mid-point between the pulleys on the hydrostats and T-box.
  • Page 34 CARE AND MAINTENANCE PARKING BRAKE CABLE ADJUSTMENT: Make necessary adjustments to the T-Box to Hydrostat belt, as shown on page 30. Position parking brake lever in the off or disengaged position. This will allow the belt idler used on the engine to T-box to swing fully and apply tension to the belt.
  • Page 35 CARE AND MAINTENANCE NEUTRAL ADJUSTMENT: 1. Engage parking brake, and raise rear of frame with jack or blocks so that rear tires do not contact the ground. 2. Swing out the control levers, start the engine, and release the parking brake. 3.
  • Page 36 CARE AND MAINTENANCE 6. Drive machine with both levers in top speed position. If one side now drives slightly faster than the other adjust forward speed bolt in to contact stop sooner. If levers are now uneven at top speed, loosen control lever mounting nut. Rotate lever to be even with other side and tighten nut.
  • Page 37 CARE AND MAINTENANCE PROCEDURE FOR ELECTRIC CLUTCH ADJUSTMENT Electric clutches require periodic Air Gap adjustments for extended life. Listed below is both an Air Gap adjustment procedure and an Ohms test to check for a faulty coil within the clutch. No replacement parts are available to repair a faulty assembly.
  • Page 38 CARE AND MAINTENANCE HYDROSTATIC TRANSMISSION OIL AND FILTER SERVICE SERVICE INTERVALS: OIL REQUIREMENTS: RECOMMENDED OIL WEIGHT: OIL FILTER: DO NOT: Page 36 1 . Initial oil and filter service - 50 hours. 2. Every 250 hours thereafter. Any high quality engine oil with an API classification of SG/CD is recommended.
  • Page 39 1. Remove oil filter from chassis, allowing oil to drain into container. Clean impurities from inside of reservoir, if necessary. 2. Install new oil filter to chassis. Use only genuine Dixon replacement oil filter. 3. Put fresh oil in reservoir. Fill reservoir to the full mark.
  • Page 40 The serial number is located on frame at rear of engine. Refer to Warranty Registration Form (P/N 8289). See your Dixon dealer for replacement parts, warranty or service. ANIMALS IN YOUR AREA...

  • Page 41: Standard Service Parts List

    STANDARD SERVICE PARTS LIST 42" DECK BLADES: LoLift: Standard Hi-Lift: BELTS: Engine To Mower Deck: Serpentine Belt: Engine To T-Box: Engine To T-Box: T-Box To Hydros: 50" DECK Grass Blower Belt: BLADES: Lo Lift: Standard Hi-Lift: BELTS: Engine To Mower Deck: Serpentine Belt: Engine To T-Box: Engine To T-Box:...
  • Page 42 STANDARD SERVICE PARTS LIST KOHLER AIR AND OIL FILTER PART NUMBERS: Refer to engine manufacturers manual for recommendations regarding frequency of service required for engine oil changes and air filter maintenance. Protect your engine investment, use only original equipment filters. Model ZTR 5022: 22HP Page 40...

  • Page 43: Troubleshooting

    Examination of one or more of the above will generally produce a quality cut. The Troubleshooting Chart suggests practices and adjustments that may be helpful in improving cut quality. Your Dixon ZTR dealer is also available to provide assistance to you. SITUATION CAUSES...
  • Page 44 TROUBLESHOOTING CAUSES REMEDY Refer to page 33 for procedure or consult your dealer for repair Replace with correct Dixon filter Consult your dealer for repairs Continued attempted operation may result in damage to the system Consult your dealer for repairs...
  • Page 45 ELECTRICAL SYSTEM: SITUATION Starter will not Circuit breaker turn engine over disengaged Dead battery Starter will not turn engine over Battery discharge Poor connections on battery Battery water low Wrong battery installed in mower Battery discharge Engine electrical system not functioning correctly Battery discharge Engine being operated at too low an RPM...
  • Page 46 NOTES...
  • Page 47 DIXON INDUSTRIES, INC. A BLOUNT International Inc.Co. PO BOX 1569 COFFEYVILLE KS 67337 0945 316251 2000 OWNER INFORMATION...
  • Page 48 The Engine Exhaust from this product contains chemicals known to the WARNING: State of California to cause cancer, birth defects or other reproductive harm. ® Dixon and ZTR are registered trademarks of Dixon Industries, Inc. DIXON INDUSTRIES, INC. A BLOUNT International Inc. Co. PO BOX 1569...

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