Dixon 5000 Series Operator's Manual
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Dixon 5000 Series Operator's Manual

Dixon 5000 Series Operator's Manual

Ztr 5000 series
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  • Page 2 The information in this operator's manual applies to all Dixon 5000 Series Model Mowers. Your Dixon dealer will gladly provide a check-out ride and answer any questions.

  • Page 3: Table Of Contents

    INDEX SAFETY ............Pages 1 - 6 WARRANTY POLICY.........Page SPECIFICATIONS..........Page 8 - 1 0 SEAT ADJUSTMENT .........Page CONTROLS............Pages 12- 15 OPERATION INSTRUCTIONS ......Pages 16- 23 CARE AND MAINTENANCE.......Pages 24 - 38 STANDARD SERVICE PARTS LIST ....Page 39 - 40 TROUBLESHOOTING ........Pages 41 -43 DIAGRAMS............Pages 44- 62 Part No.

  • 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... TIP-OVER Page 1...
  • Page 5 SAFETY SAFETY SYMBOLS: 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.

  • 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 serious injury or death. GENERAL OPERATION: Read, understand, and follow all instructions in the manual and on the mower before starting. Only allow responsible adults, who are familiar with the instructions, to operate the mower.

  • 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 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.

  • Page 10: Warranty Policy

    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. DIXON ZTR MOWERS ARE WARRANTED AGAINST DEFECTS IN MATERIALS AND WORKMANSHI P AND PROVIDES FOR REPLACEMENT OR REPAIR OF PARTS INCLUDING LABOR COSTS.

  • Page 11: Specifications

    SPECIFICATIONS Model ZTR 5422 CHASSIS: 11 GA - rectangular tube Two piece - made of rotational molded polyethylene. Front body contains BODY: 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.
  • Page 12 SPECIFICATIONS Model ZTR 5502 CHASSIS: 1 1 GA - rectangular tube Two piece - made of rotational molded polyethylene. Front body contains BODY: 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: Ergonomically designed for operator comfort by use of high density closed cell foam, contoured back rest and arm rests.
  • Page 13 SPECIFICATIONS Model ZTR 5601 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. Ergonomically designed for operator comfort by use of high density closed cell SEAT: foam, contoured back rest and arm rests.

  • Page 14: Seat Adjustment Instructions

    SEAT ADJUSTMENT INSTRUCTIONS Models ZTR 5422 - ZTR 5502 - ZTR 5601 : Place parking brake in ON position. (Pull brake lever up) Raise and push seat assembly and upper body rearward. Loosen two front seat adjustment knobs, P/N 3978, and slide seat forward or backward to desired position.

  • Page 15: Controls

    Page 12 CONTROLS...
  • Page 16 CONTROLS 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. CAUTION Engage parking brake before starting engine.
  • Page 17 CONTROLS 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 18 CONTROLS BLADE DRIVE: Located on control panel, on operator's right. To engage the mower blades, lift switch up lightly and push forward. To disengage blades, pull switch backward. Switch is clearly marked "on and off". CIRCUIT BREAKER: Located on control panel, on operator's right. Protection of the electrical system is by (1)15 amp circuit breaker.

  • Page 19: 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 20 BLADE DRIVE SWITCH TEST: (5000 Series) a. With electric blade drive switch turned ON and parking brake in the ON position,...
  • Page 21 OPERATION INSTRUCTIONS STARTING INSTRUCTIONS: Cold Engine 1 . Push choke control lever fully forward. 2. Push throttle control lever to 1/2 setting. 3. Insert ignition key and turn to "Start" position. When engine starts, release ignition key. Key will return to "Run" position. 4.
  • Page 22 OPERATION INSTRUCTIONS STARTING INSTRUCTIONS: Engine has been operated. Move throttle control lever to 1/4 to 1/2 setting. Insert ignition key and turn to "Start" position. When engine starts, release ignition key. Key will return to "Run" position. Move throttle control lever to wide open or maximum setting for actual operation of the mower deck.
  • 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 on page 41. Be sure that deflector is properly installed on the CAUTION discharge chute.
  • Page 26 OPERATION INSTRUCTIONS DECK ROLLERS: The spring loaded deck rollers located at the front corners of the mower deck are Purpose: 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 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 - 5000 SERIES MODELS CUTTER BLADE MAINTENANCE: NOTE: Observe proper blade position prior to removal. Safely raise front of mower. Hold or block blade from turning. Wear heavy, thick gloves when holding onto cutter blade, CAUTION avoid the sharp edge of the blade.
  • Page 29 CARE AND MAINTENANCE - 5000 SERIES MODELS BELT TENSION ENGINE TO MOWER DECK BELT: Models ZTR 5422 & ZTR 5502 P/N 61 1 1 Model ZTR 5601 P/N 6939 MOWER DECK SERPENTINE BELT: Model ZTR 5422 P/N 6109 Model ZTR 5502...
  • Page 30 CARE AND MAINTENANCE - 5000 SERIES MODELS 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.
  • Page 31 CARE AND MAINTENANCE - 5000 SERIES MODELS 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.
  • Page 32 3. Refill engine with type, and quantity of oil recommended by the engine manufacturer in engine literature. NOTE: Engine oil changes on the 5000 Series Models will require replacement of the oil filter. These filters can be obtained from any authorized Kohler engine dealer.
  • Page 33 CARE AND MAINTENANCE - 5000 SERIES MODELS MOWER DECK INSTALLATION: NOTE: Brake link (P/N 5283) normally used for installation of engine to mower deck drive belt, has been placed in position during assembly of the lift frame at the factory. For shipment purposes, the brake link has been secured with a cotter pin and washer.
  • Page 34 CARE AND MAINTENANCE - 5000 SERIES MODELS 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 - 5000 SERIES MODELS 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 - 5000 SERIES MODELS PARKING BRAKE CABLE ADJUSTMENT: 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 - 5000 SERIES MODELS NEUTRALADJUSTMENT: Swing upper control levers out into the neutral slots. Raise upper body to the fully open position. Start engine and disengage parking brake. Caution should be used when releasing parking brake as mower may tend to creep or move prior to adjustment.
  • Page 38 CARE AND MAINTENANCE - 5000 SERIES MODELS FORWARD TRAVEL SPEED ADJUSTMENTS: Stop engine, move levers to drive position, lightly push each upper control lever forward until a resistance is felt on the lever. At this time, check that the forward lever stops on the bottom of each lever are hitting the stop blocks.
  • Page 39 CARE AND MAINTENANCE - 5000 SERIES MODELS PROCEDURE FOR ELECTRIC CLUTCH ADJUSTMENT Electric clutches require periodic Air Gap adjustments to extend the life of the clutch. Listed below is both an Air Gap adjustment procedure and an Ohms test to check for a faulty coil within the clutch.
  • Page 40 CARE AND MAINTENANCE - 5000 SERIES MODELS 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.
  • Page 41 CARE AND MAINTENANCE - 5000 SERIES MODELS WHEELS AND TIRES: Correct tire pressure is important for correct operation of mower. Model ZTR 5422 Front Tires 1 1 X 4 X 4 Air Pressure 16-21 Ibs. Rear Tires 18 X 9.50 X 8 Air Pressure 8-14 Ibs.

  • Page 42: Standard Service Parts List

    Page 39 STANDARD SERVICE PARTS LIST MODEL ZTR 5422: BLADES: Standard: P/N 6236 Hi-Lift: P/N 8688 BELTS: Engine To Mower Deck: P/N 61 1 1 Serpentine Belt: P/N 6109 Engine To T -Box: P/N 1714 T-Box To Hydros: P/N 1765 Grass Blower Belt: P/N 4983 MODEL ZTR 5502:...
  • Page 43 IMPORTANT: Some applications, extreme dirt conditions, or the use of a grass catcher may require that the engines used on the 5000 Series Models be fitted with an OPTIONAL Kohler fresh air filter system. Listed below are the Kohler kit numbers required to adapt these components to the various engines.

  • Page 44: 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 45 TROUBLESHOOTING DRIVE SYSTEM: t' - SITUATION CAUSES REMEDY Drive adjustment Consult your dealer for repair Mower pulls to one side or the other Incorrect oil filter Drive system will not Replace with correct Dixon P/N installed on system function on either side 5565 filter Consult your dealer for repairs after changing...
  • Page 46 TROUBLESHOOTING ELECTRICAL SYSTEM: SITUATION CAUSES REMEDY Circuit breaker engaged Starter will not Push button to reset Consult turn engine over your dealer for repair Dead battery Charge battery Starter will not turn engine over Battery discharge Tighten or replace as required Poor connections on battery Battery water low...

  • Page 47: Diagrams

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  • Page 66 DIXON INDUSTRIES, INC A BLOUNT COMPANY AIRPORT INDUSTRIAL PARK PO BOX 1569 COFFEYVILLE KS 67337 O945 316 251 2OOO F A X 3 1 6 2 5 1 4 1 1 7 OWNER INFORMATION DATE PURCHASED MOWER MODEL NUMBER PURCHASED FROM Name Address MOWER SERIAL NUMBER...
  • Page 67 NOTES...
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  • Page 71 NOTES...
  • Page 72 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 Part No. 8965 BLOUNT COM PAN Y September 1995 AIRPORT INDUSTRIAL PARK PO...

This manual is also suitable for:

Ztr 5422Ztr 5502Ztr 5601

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