Dixon ZTR 5000 Series manual

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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. The information in this operato[...]

INDEX SAFETY ............................. ................. ........ Pages 2 - WARRANTY POLICY ............................. ........ Page 8 SPECIFICATIONS ................................. ........ Page 9 SEAT ADJUSTMENT ............................. ........ Page CONTROLS .......................................... ........ Pages 11 - 14 OPERATIO[...]

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[...]

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 r[...]

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. • Only allow responsible adults, who are familia[...]

SAFETY 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 cannot back up the slope or if you feel uneasy on it, do not mow it. DO Mow across the slope w ith your Dixon ZTR - never up or down. Remove obstacles such as[...]

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. • Keep children out of the mowing area and under the watchful care of another responsible adult[...]

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. Never store the mower or fuel container inside a building[...]

DIXON LIMITED WARRANTY POLICY -- HYDRO - GEAR MODELS 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. Mowers used for resi dential homeowner applications (use[...]

SPECIFICATIONS Model ZTR 5022 CHASSIS: 1 1 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 c omfort, contoured back rest an[...]

SEAT ADJUSTMENT INSTRUCTIONS Model ZTR 5022: 1. Set parking brake. 2. Raise upper body. 3. Loosen two front seat adjustment knobs and slide seat forward or backward tc desired position. 4. Re - tighten front seat adjustment knobs. DO NOT operate mower without seat adjustments properly tightened. 5. Carefully lower upper body and seat assembly to th[...]

5000 Series CONTROLS Page 11[...]

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. Engage parking brake before starting engine Do not leave engine running for extended periods of time without the parking brake engaged. Damage to the drive system[...]

CONTROLS TO GO FORWARD: From neutral position, gently push both drive levers forward. To increase speed, move levers fa rther 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 rear[...]

BLADE DRIVE: CONTROLS 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. Protect[...]

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. First - time[...]

OPERATION INSTRUCTIONS PARKING BRAKE SWITCH TEST: With parking brake in the OFF position, engine should not turn over or attempt to start when the key switch is moved to the start position. BLADE DRIVE SWITCH TEST: (5000 Series) a. With electric blade drive switch turned ON and parking brake in the ON position, engine should not turn over or attemp[...]

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. Once engine starts to warm up, slowly move cho[...]

OPERATION INSTRUCTIONS STARTING INSTRUCTIONS: Engine has been operated. 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[...]

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 instan ces or conditions where it is not possible to hide all of the recycled or mulched clippings. In order to achieve the bes[...]

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: 1. Set engine speed control to the wide open or full setting. 2. Do Not Attempt To Cut Grass When It Is Wet. Wet grass will clog both the underside of the [...]

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. 1. Set engine speed [...]

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. This setting sho[...]

CARE AND MAINTENANCE This portion of the 5000 Series Models owners manual deals with normal service items which can be performed by the owner. Please remember that if you are in doubt as to the correct service procedures to be followed, these and other service situations can b e handled by a Dixon ZTR dealer who is familiar with the service of your[...]

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 re m ove blade. Wear heavy, th ick gloves when holding onto mower blade, avoid the sharp edqe of the b | ade. 4. Tighten blade nut securely. Refer to diagram[...]

CARE AND MAINTENANCE 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. MOWER DECK SERPENTINE BELT: 42" P/N 610 9 50" P/N 1300 60&qu[...]

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: RECOMMENDED GREASE: Number of grease zerks used: (5) (1) each front wheel caster tube (1) ea[...]

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 [...]

CARE AND MAINTENANCE HOT oil may cause burns. 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 wil l help direct the oil. 3. Push the valve body in and twist[...]

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 c ut positon. Belt can now be removed from mower deck pulley. 2. Remove front and rear deck hanger pins, as illustrated below. 3. Slide deck from be[...]

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. Deck should be level or pitched slightly higher in rear. A. Plac[...]

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 hydros[...]

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 use d on the engine to T - box to swing fully and apply tension to the belt. At this time, check that the cable has appr[...]

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. Raise the upper body to access hydro control linkage. If right wheel creeps, adjust right side linkage and vi[...]

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. FORWARD TRAVEL SPEED ADJUSTMENT: 1[...]

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. Th e entire clutch must be replace[...]

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 - 1[...]

CARE AND MAINTENANCE HYDROSTATIC TRANSMISSION OIL AND FILTER SERVICE If transmission is to be serviced, proper air purging procedures must be followed, or damage will occur. Proceed as follows: 1. Remove oil filter from ch assis, allowing oil to drain into container. Clean impurities from inside of reservoir, if necessary. 2. Install new oil filter[...]

CARE AND MAINTENANCE WHEELS AND TIRES: Correct tire pressure is important for correct operation of mower. Air Pressure 16 - 21 Ibs. (Front) Air Pressure 8 - 14 Ibs. (Rear) NOTE: Check lug nuts periodically for tightness. ELECTRICAL SYSTEMS: Keep all connections clean and tight. CLEANING THE MOWER: Wash mower periodically. Clean above and below deck[...]

STANDARD SERVICE PARTS LIST 42" DECK BLADES: LoLift: P/N 6236 Standard Hi - Lift: P/N8688 BELTS: Engine To Mower Deck: P/N6111 Serpentine Belt: P/N6109 Engine To T - Box: P/N 171 4(1 998 models) Engine To T - Box: P/N 7253(1 999 models) K 5 ' T - Box To Hydros: P/N 1765 50" DECK Grass Blower Belt: P/N 4983 BLADES: Lo Lift: P/N 9443 S[...]

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 Pre - Cleaner Foam Element 45083 - 01 Cartri[...]

TROUBLESHOOTING MOWER CUT QUALITY: There are many variables that can affect the cut quality of any riding mower. Type and conditions of grass, cut height setting, engine RPM and ground speed are some of the variables that interact creating differences in cut quality. Examination of one or more of the above will generally produce a quality cut. The [...]

TROUBLESHOOTING DRIVE SYSTEM: SITUATION CAUSES REMEDY Mower pulls to one side or the other Forward travel speed adjustment Refer to page 33 for procedure or consult your dealer for repair Drive system will not function on either side after changing hydrostatic transmission oil and filter Incorrect oil filter installed on system Hydrostatic transmis[...]

TROUBLESHOOTING ELECTRICAL SYSTEM: SITUATION CAUSES REMEDY Starter will not turn engine over Circuit breaker disengaged Push button to reset Consult your dealer for repair Starter will not turn engine over Dead battery Charge battery Battery discharge Poor connections on battery Battery water low Wrong battery installed in mower Tighten or replace [...]

NOTES[...]

DIXON INDUSTRIES, INC. A BLOUNT International Inc.Co. PO BOX 1569 COFFEYVILLE KS 67337 0945 316251 2000 OWNER INFORMATION[...]

WARNING: The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive ha rm. ® Dixon and ZTR are registered trademarks of Dixon Industries, Inc. DIXON INDUSTRIES, INC. A BLOUNT International Inc. Co. PO BOX 1569 COFFEYVILLE KS 67337 0945 3162512000 5000 Series Part No[...]