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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. See your dealer for warranty service, parts and repairs.

  • Page 3: Table Of Contents

    INDEX SAFETY..............Pages 1- 5 WARRANTY POLICY..........Page SPECIFICATIONS............. Page 7- 9 SEAT ADJUSTMENT ..........Page CONTROLS...............Pages 11 -1 4 OPERATION INSTRUCTIONS.........Pages 15 -19 CARE AND MAINTENANCE......... ….Pages 20 - 41 STANDARD SERVICE PARTS LIST..... ….Page 42 - 43 TROUBLESHOOTING..........Pages 4 4- 4 6 10.

  • 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... BLADE CONTACT TIP-OVER RUN-OVER To avoid these and other accidents, read and understand the operator's manual. SAFETY SYMBOLS: SAFETY ALERT SYMBOL - When you see this symbol, BE ALERT to the potential for injury.

  • Page 5: General Operation

    SAFETY 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. •...

  • Page 6: 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 7 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 8 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 9: 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 WORKMANSHIP AND PROVIDES FOR REPLACEMENT OR REPAIR OF PARTS INCLUDING LABOR COSTS.

  • Page 10: Specifications

    SPECIFICATIONS Model ZTR 5421 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.
  • Page 11 SPECIFICATIONS Model ZTR 5501 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: Economically designed for operator comfort by use of high density closed cell foam, contoured back rest and arm rests.
  • Page 12 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. SEAT: Economically designed for operator comfort by use of high density closed cell foam, contoured back rest and arm rests.

  • Page 13: Seat Adjustment Instructions

    SEAT ADJUSTMENT INSTRUCTIONS Models ZTR 5421 - ZTR 5501 - 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 14: Controls

    CONTROLS...
  • Page 15 CONTROLS PARKING BRAKE: The parking brake used on the 5000 Series Models is designed to hold the mower from moving and is noHntended for use in stopping the mower while it is in motion. CAUTION Engage parking brake before starting engine.
  • Page 16 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 b oth 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 17 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 18: Operation Instructions

    OPERATION INSTRUCTIONS The safe and successful operation of the 5000 Series Models will depend upon the operator h aving 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 19 OPERATION INSTRUCTIONS STARTING INSTRUCTIONS: Engine has been operated. 1. Move throttle control lever 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 lever to wide open or maximum setting for actual operation of the mower deck.
  • Page 20 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.
  • Page 21 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 22 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 44. CAUTION Be sure that detector is properly installed on the discharge chute 1.
  • Page 23 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 24 CARE AND MAINTENANCE - 5000 SERIES MODELS CUTTER BLADE MAINTENANCE: NOTE: Observe proper blade position prior to removal. 1. Safely raise front of mower. 2. Hold or block blade from turning. CAUTION Wear heavy, thick gloves when holding onto cutter blade, avoid the sharp edge of the blade.
  • Page 25 CARE AND MAINTENANCE - 5000 SERIES MODELS BELT TENSION ENGINE TO MOWER DECK BELT: Models ZTR 5421 & ZTR 5501 P/N 6111 Model ZTR 5601 P/N 6939 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 26 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 27 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 28 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. PROTECT YOUR INVESTMENT: The use of non-original oil or air filters may result in damage to the engine and a loss of warranty.
  • Page 29 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 30 CARE AND MAINTENANCE - 5000 SERIES MODELS MOWER DECK LEVELING PROCEDURE: There are a total of (4) threaded adjusters which will control the atti tude 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 31: Care And Maintenance

    CARE AND MAINTENANCE MODEL ZTR 5421 DRIVE SYSTEM ADJUSTMENTS Successful adjustment of the Model ZTR 5421 "twisted" drive belt depends on a number of factors which must be observed. • If the "twisted" drive belt P/N 1860 has broken or is of a high hour use nature, replacement of belts, P/N 1859, that drive each hydrostatic transmission will be required due to belt stretch and wear.
  • Page 32 CARE AND MAINTENANCE MODEL ZTR 5421 DRIVE SYSTEM ADJUSTMENTS TWISTED BELT ADJUSTMENT: 1. Check routing of belt P/N 1860 from engine to triple drive pulley P/N 1850. Belt must be routed inside of welded tab on engine mount. Incorrect routing will result in a loss of clutching action when parking brake is engaged.
  • Page 33 CARE AND MAINTENANCE MODEL ZTR 5421 DRIVE SYSTEM ADJUSTMENTS TWISTED BELT ADJUSTMENT: 3. VISUAL BELT ALIGNMENT CHECK: A. .Stand on left side of mower. Disengage parking brake and observe engagement action of pulley P/N 1751 against drive belt P/N 1860. B.
  • Page 34 CARE AND MAINTENANCE MODEL ZTR 5421 DRIVE SYSTEM ADJUSTMENTS TWISTED BELT ADJUSTMENT: 5. The idler pulley travel required to engage the belt drive should be held to approximately 1 3/4". A. To adjust this distance, loosen the nuts on both ends of the rod extending between the idler plate and the brake shaft.
  • Page 35 CARE AND MAINTENANCE MODEL ZTR 5421 DRIVE SYSTEM ADJUSTMENTS BRAKE BAND ADJUSTMENTS: Located on each gearbox. Brake handle should be placed in both "off" and "on" positions several times to determine whether each brake band is functioning correctly. The brake bands should fit tightly around brake drums with the brake handle "on" or pulled upward.
  • Page 36 CARE AND MAINTENANCE MODEL ZTR 5421 DRIVE SYSTEM ADJUSTMENTS 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 37 CARE AND MAINTENANCE MODEL ZTR 5421 DRIVE SYSTEM ADJUSTMENTS NEUTRAL ADJUSTMENT: Swing upper control levers out into the neutral slots. s; 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 MODELS ZTR 5501 & ZTR 5601 DRIVE SYSTEM ADJUSTMENTS 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 39 CARE AND MAINTENANCE MODELS ZTR 5501 & ZTR 5601 DRIVE SYSTEM ADJUSTMENTS 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 40 CARE AND MAINTENANCE MODELS ZTR 5501 & ZTR 5601 DRIVE SYSTEM ADJUSTMENTS NEUTRAL ADJUSTMENT: Swing upper control levers out into the neutral slots. Raise upper body to the fully open po sition. 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 41 CARE AND MAINTENANCE MODELS ZTR 5501 & ZTR 5601 DRIVE SYSTEM ADJUSTMENTS 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 42 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. No replacement parts are available to repair a faulty assembly.
  • Page 43 CARE AND MAINTENANCE - 5000 SERIES MODELS HYDROSTAT IC TRANSMISSION OIL AND FILTER SERVICE 1. Initial oil and filter service - 50 hours. SERVICE INTERVALS: 2. Every 250 hours thereafter. OIL REQUIREMENTS: Any high quality engine oil with an API classification of SG/CD is recommended.
  • Page 44 CARE AND MAINTENANCE - 5000 SERIES MODELS WHEELS AND TIRES: Correct tire pressure is important for correct operation of mower. Model ZTR 5421 Front Tires 1 1 X 4 X 4 Air Pressure 16-21 Ibs. Rear tires 1 8 X 9 . 5 0 X 8 Air Pressure 8-14 Ibs.

  • Page 45: Standard Service Parts List

    STANDARD SERVICE PARTS LIST MODEL ZTR 5421: Standard: Hi- P/N 6236 BLADES: Lift: P/N 8688 BELTS: Engine To Mower Deck: P/N 6111 Serpentine Belt: P/N 6109 Hydrostat Drive Belt: P/N 8772 (set of two) Engine To Drive Pulley: P/N 1860 Grass Blower Belt: P/N 4983 MODEL ZTR 5501:...
  • Page 46 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 47: Troubleshooting

    Examination of one or more of t he 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 48 TROUBLESHOOTING DRIVE SYSTEM: SITUATION CAUSES REMEDY Drive adjustment Consult your dealer for repair Mower pulls to one side or the other Drive belt from engine to Faulty belt or incorrect * Carefully follow EACH step in the triple pulleys is thrown off adjustment procedures shown on belt is installed when parking brake is...
  • Page 49 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 50 5421 Drive Pulley/Hydro/Gearbox...
  • Page 51 5501 T-Box/Hydro/Gearbox...
  • Page 52 5601 T-Box/Hydro/Gearbox...
  • Page 53 5000 Series Gearbox...
  • Page 54 5421 Mower Deck...
  • Page 55 5501 Mower Deck...
  • Page 56 5601 Mower Deck...
  • Page 57 5421 Chassis...
  • Page 58 5501 Chassis...
  • Page 59 5601 Chassis...
  • Page 60 5421 Fuel/Hydro Tanks & Fittings...
  • Page 61 5501 Fuel/Hydro Tanks & Fittings...
  • Page 62 5601 Fuel/Hydro Tanks & Fittings...
  • Page 63 5421 Body...
  • Page 64 5501 Body...
  • Page 65 5601 Body...
  • Page 66 5421 Wiring...
  • Page 67 5501 Wiring...
  • Page 68 5601 Wiring...

  • Page 69: Owner Information

    DIXON INDUSTRIES, INC A BLOUNT COMPANY AIRPORT INDUSTRIAL PARK PO BOX 1569 COFFEYVILLE KS 67337 O945 316 251 2OOO FAX 316 251 4117 OWNER INFORMATION DATE PURCHASED MOWER MODEL NUMBER PURCHASED FROM MOWER SERIAL NUMBER DATE OIL CHANGED: DATE ENGINE TUNED:...

This manual is also suitable for:

Ztr 5421Ztr 5501Ztr 5601

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