Dixon ZTR 5000 series Operator's Manual
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Dixon ZTR 5000 series Operator's Manual

Dixon ZTR 5000 series Operator's Manual

Ztr 5000 series
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1999 Operator's Manual
5000
SERIES
Page
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Summary of Contents for Dixon ZTR 5000 series

  • Page 1 1999 Operator's Manual 5000 SERIES Page...
  • Page 2 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. The information in this operator's manual applies to all Dixon 5000 Series ®...

  • Page 3: Table Of Contents

    INDEX SAFETY ..............Pages 2 - 7 WARRANTY POLICY..........Page 8 - 9 SPECIFICATIONS..........Page 10 - 12 SEAT ADJUSTMENT ..........Page CONTROLS ............Pages 14 - 17 OPERATION INSTRUCTIONS ........ Pages 18 - 24 CARE AND MAINTENANCE ........Pages 25 - 40 STANDARD SERVICE PARTS LIST......

  • Page 4: Safety

    SAFETY SAFETY SAFETY SAFETY SAFETY RIDING LAWNMOWERS, IF IMPROPERLY OPERATED, CAN CAUSE SERIOUS INJURY OR DEATH The most common causes of injury to the operator or bystander... BLADE CONTACT TIP-OVER BACK-OVER RUN-OVER ...read and understand this manual to prevent injuries. Page 4...

  • Page 5: Safety Alert Symbol

    SAFETY SAFETY SAFETY SAFETY SAFETY SAFETY SY SAFETY SY SAFETY SY SAFETY SY SAFETY SYM M M M M BOLS BOLS BOLS BOLS BOLS Safety Alert Symbol When you see this symbol, BE ALERT to the potential for injury. Follow recommended safety precautions and safe operating practices.

  • Page 6: General Operation

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

  • Page 7: Slope Operation

    All slopes require extra caution. 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 SAFETY 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. •...

  • Page 9: Safety

    SAFETY 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 Commercial Hydrostatic mowers, 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. Mowers used for residential homeowner applications (used only at owner's primary place of residence) are warranted for two (2) years from date of purchase or 400 hours of use, whichever occurs first.

  • Page 11: Warranty Policy

    Dixon Industries, Inc. VOIDS ALL WARRANTY. The following items are not covered by this warranty policy: (a) Pick up and delivery charges for transportation of mower to and from an Authorized Dixon Dealer's place of business. (b) Routine maintenance or adjustments.

  • Page 12: Specifications

    SPECIFICATIONS Model ZTR 5017 CHASSIS: 11 GA - rectangular tube BODY: Two piece - made of rotational molded 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: Designed for operator comfort by use of high density closed cell foam padded back and arm rests, upholstered with Cordura...
  • Page 13 SPECIFICATIONS Model ZTR 5020 CHASSIS: 11 GA - rectangular tube BODY: Two piece - made of rotational molded 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: Designed for operator comfort by use of high density closed cell foam padded back rest and arm rests, upholstered with Cordura...

  • Page 14: Specifications

    SPECIFICATIONS Model ZTR 5022 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: Designed for operator comfort by use of high density closed cell foam padded back and arm rests, upholstered with Cordura...

  • Page 15: Seat Adjustment

    SEAT ADJUSTMENT INSTRUCTIONS 5000 Series Models Grasp seat slide adjuster and move it into adjustment position. Slide seat forward or backward. Release seat slide adjuster. Page...

  • Page 16: Controls

    CONTROLS Page 16...
  • Page 17 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. CAUTION Engage parking brake before starting engine TO SET PARKING BRAKE: The hand operated parking brake is located at left hand side of mower.
  • Page 18 CONTROLS (left turn opposite) 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 19: Controls

    CONTROLS BLADE DRIVE: Located on control panel, on operator's right. To engage blades: Pull up on the switch. To disengage blades: Push down. CIRCUIT BREAKER: Located on control panel, on operator's right. Protection of the electrical system is by (1) 15 amp circuit breaker. If circuit breaker trips, push button to reset.

  • Page 20: Operation Instructions

    OPERATION INSTRUCTIONS Safe and successful operation 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 21: Testing Of Safety Interlock Systems

    Engage blade drive switch c) Raise slightly off seat ENGINE SHOULD STOP 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...
  • Page 22 OPERATION INSTRUCTIONS STARTING INSTRUCTIONS: Cold Engine 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 23 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 24 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 25 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. Be sure that deflector is properly installed on the CAUTION discharge chute.

  • Page 26: Operation Instructions

    OPERATION INSTRUCTIONS DECK ROLLERS: 60" Deck Purpose: The spring loaded deck rollers located at the front corners of the 60" mower deck are designed as an aid to limit turf scalping when mowing on uneven ground. Height: Normal height settings as installed at the factory allows each roller to ride slightly above the turf.

  • Page 27: 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 28 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. When replacing blade, tighten blade nut securely. Refer to diagram. Wear heavy, thick gloves when holding onto mower blade, avoid the CAUTION sharp edge of the blade.
  • Page 29 CARE AND MAINTENANCE BELT TENSION ENGINE TO MOWER DECK BELT: 42' and 50" P/N 6111 60" P/N 6938 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 30 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: Number of grease zerks used: (5) LOCATIONS:...
  • Page 31 CARE AND MAINTENANCE 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 32 CARE AND MAINTENANCE HOT oil may cause burns. CAUTION Allow engine to cool before draining oil. 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.
  • Page 33 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. INSERT END OF LINK HERE 5283...
  • Page 34 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 35 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 36 CARE AND MAINTENANCE PARKING BRAKE CABLE ADJUSTMENT: Make necessary adjustments to the T-Box to Hydrostat belt, as shown on page 32. 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 37 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 38 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 39 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 40 CARE AND MAINTENANCE HYDROSTATIC TRANSMISSION OIL AND FILTER SERVICE SERVICE INTERVALS: 1. Initial oil and filter service - 50 hours. 2. Every 250 hours thereafter. OIL REQUIREMENTS: Any high quality engine oil with an API classification of SG/CD is recommended. RECOMMENDED OIL WEIGHT: Normal operation temperatures - 20 W 50 Cold climate usage - 10 W 40...
  • Page 41 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 42: Care And Maintenance

    The serial number is located on frame at rear of engine. WARRANTY: Refer to Warranty Registration Form. PARTS/SERVICE: See your Dixon dealer for replacement parts, warranty or service. PLEASE HELP PROTECT THE ENVIRONMENT BY AVOIDING ALL CHEMICALS WHICH MAY DAMAGE OR CAUSE HARM TO PLANTS AND...

  • Page 43: Standard Service Parts List

    STANDARD SERVICE PARTS LIST 42" DECK BLADES: Lo Lift: P/N 6236 Standard Hi-Lift: P/N 8688 BELTS: Engine To Mower Deck: P/N 6111 Serpentine Belt: P/N 6109 Engine To T-Box: P/N 7253 T-Box To Hydros: P/N 1765 Grass Blower Belt: P/N 4983 50"...

  • Page 44: Standard Service Parts List

    STANDARD SERVICE PARTS LIST KOHLER AND BRIGGS & STRATTON 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. Kohler 22HP Pre-Cleaner Foam Element...

  • Page 45: 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 46 Refer to page 35 for procedure side or the other speed adjustment or consult your dealer for repair Drive system will not Incorrect oil filter installed Replace with correct Dixon function on either side on system filter after changing hydrostatic transmission...

  • Page 47: Troubleshooting

    TROUBLESHOOTING ELECTRICAL SYSTEM: SITUATION CAUSES REMEDY Starter will not Circuit breaker Push button to reset turn engine over disengaged Consult your dealer for repair Starter will not Dead battery Charge battery turn engine over Battery discharge Poor connections on Tighten or replace as required battery Battery water low Wrong battery installed...
  • Page 48 NOTES Page 48...
  • Page 49 DIXON INDUSTRIES, INC. A BLOUNT International Inc. Co. PO BOX 1569 COFFEYVILLE KS 67337 0945 316 251 2000 FAX 316 251 4117 OWNER INFORMATION DATE PURCHASED MOWER MODEL NUMBER PURCHASED FROM Name Address MOWER SERIAL NUMBER DATE OIL CHANGED: DATE ENGINE TUNED:...
  • Page 50 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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