Dixon ZTR 5004 manual

5000 SERIES ZTR ® 2003 OPERATORS MANUAL[...]

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 contained in this [...]

3 INDEX Page Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-14 Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . . . . . . . .15 Controls[...]

4 RIDING LAWN MOWERS, 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. BLADE CONTACT TIP OVER RUN OVER BACK OVER SAFETY[...]

5 Safety Alert Symbol When you see this symbol, BE ALERT to the potential for injury. DANGER (highlighted in red) indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING (highlighted in orange) indicates a potentially hazardous situation which, if not avoided, could result in death or serio[...]

6 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. Clear the area of objects such as rock[...]

7 GENERAL OPERATION (continued) : Turn off blades when not mowing. Stop engine before removing grass catcher or unclogging chute. Mow only in daylight or good artificial light. Do not operate the mower while under the influence of alcohol or drugs. Watch for traffic when operating near or crossing roadways. Use extra care when loa[...]

8 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 with your Dixon ZTR - never up or down.  Remove obstacles such as ro[...]

9 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 adu[...]

10 SERVICE:  Use extra care in handling gasoline and other fuels. They are flammable and vapors are explosive. Use only an approved container. Never remove fuel cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke while refueling. Never refuel the mower indoors. Never store the mower or fuel container inside a[...]

11 SERVICE (continued):  Never run a mower inside a closed area. The exhaust fumes are toxic.  Keep nuts and bolts tight, especially blade attachment bolts, and keep equipment in good condition.  Never tamper with safety devices. Check their proper operation regularly.  Keep mower free of grass, leaves, or other debris buildup. Clean up[...]

12 WARRANTY: Dixon Commercial Warranty is for a period of one (1) year from date of purchase or 400 hours of use, whichever occurs first. Mowers used for Homeowner Application (used only at owners primary place of residence) are warranted for two (2) years from date of purchase. DIXON ZTR MOWERS ARE WARRANTED AGAINST DEFECTS IN MATERIALS AND WOR[...]

13 SPECIFICATIONS Model ZTR 5004/5005 CHASSIS: 11 GA - rectangular tube BODY: Two piece-made of rotational molded polyethylene. Front body contains access panels for battery service & 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 clos[...]

14 SPECIFICATIONS Model ZTR 5023 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 fo[...]

15 SEAT ADJUSTMENT INSTRUCTIONS 5000 Series Models 1 . Grasp seat slide adjuster and move it into adjustment position. 2 . Slide seat forward or backward. 3 . Release seat slide adjuster.[...]

16 CONTROLS CONTROL LEVERS Note: For access to the seat, move control levers to neutral position and swing them outward. TO GO FORWARD: • From neutral position, gently push both control levers forward. • To increase speed, move levers further forward. TO GO BACKWARD: • From neutral position, gently pull both control levers toward you. TURNING[...]

17 CONTROLS CHOKE CONTROL LEVER: • Located on control panel to operators right. • Used to start a cold engine. THROTTLE CONTROL LEVER: • Located on control panel to operators right. • Controls engine speed, slow to maximum. • While moving, throttle control should be set to MAXIMUM for wide open setting to insure adequate cooling of [...]

18 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 brake is located at the left hand side of the mower. To engage brake, pull lever up (to the rear)[...]

19 CONTROLS MOWER DECK CUT HEIGHT LIFT LEVER: • Located to the right and front of operator. • Controls the cutting height. • Seven positions of adjustment. • Depress trigger and move lever forward to lower deck. • Depress trigger and pull lever back to raise deck. NOTE: Always use high position for transport. BLADE DRIVE: • Located on c[...]

20 CONTROLS TO FREE WHEEL MACHINE (UNLOCK TRANSMISSION): Always turn off engine before engaging or disengaging the hydro release (free wheel) valves. Never attempt to move the by-pass keeper with the engine running. Move end of by-pass keepers to depress plunger (valve) at rear of each hydro pump. Release parking brake. To engage the transmission, [...]

21 OPERATION INSTRUCTIONS The safe and successful operation of the 5000 Series 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 the controls and their functions. During initi[...]

22 BEFORE OPERATING MOWER: 1. Read and observe all safety instructions on your mower and in the manual. 2. Read engine manufacturers operating and maintenance instructions. 3. Discuss proper maintenance with your dealer. 4. Check engine oil. 5. Check fuel cap to be sure it is in place. 6. Be sure parking brake is on. 7. Be sure mower blade drive[...]

23 OPERATION INSTRUCTIONS TESTING OF SAFETY INTERLOCK SYSTEMS: Do not operate mower if safety switches are not operating properly. PARKING BRAKE SWITCH TEST: a) Place parking brake in OFF position. b) Turn ignition switch to START. ENGINE SHOULD NOT TURN OVER OR ATTEMPT TO START! BLADE DRIVE SWITCH TEST: a) Place parking brake in ON position. b) En[...]

24 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. CAUTION Be sure that the deflector is properly installed on the discharge chute. 1, Set engine s[...]

25 OPERATION INSTRUCTIONS GRASS HEIGHT AND CUTTING SUGGESTIONS: Do not attempt to cut grass when it is wet. If the grass is tall, place the mower deck cut height lever in the top or second notch. Initially overlap cutting swaths instead of a full swath with each pass. Some applications may require a second cutting. As a rule of thumb, never c[...]

26 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. Note: Model 5023 may require partial choke setting to start ev[...]

27 OPERATION INSTRUCTIONS CAUTION Do not operate the engine in an enclosed area due to the harmful exhaust gas produced. 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[...]

28 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 b[...]

29 OPERATION INSTRUCTIONS MOWING WITH A MULCHING ATTACHMENT (continued): 6. Keep the Underside Of The Mower Deck Clean. Remove all grass and dirt build-up from the underside of the pan, the baffles and deflectors after each use. 7. Alternate mower direction. This will evenly disperse the mulched grass clippings over the lawn for even fertilization.[...]

30 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. Allow engine, mower deck and blower to reach full RPM before attempting to mow. 2. Do Not [...]

31 OPERATION INSTRUCTIONS MOWING WITH A GRASS CATCHER ATTACHMENT (continued): 7. Operate the mower at a slower ground speed than when mowing without a grass catching attachment. 8. Some mowing applications/use of grass catchers may require that an optional weight box be fitted to the mower to counter the weight of grass in the bags. Please consult [...]

32 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 shou[...]

33 CARE AND MAINTENANCE CAUTION CAUTION CAUTION CAUTION CAUTION Bef Bef Bef Bef Bef ore perf ore perf ore perf ore perf ore perf or or or or or ming an ming an ming an ming an ming an y maintenance y maintenance y maintenance y maintenance y maintenance , tur , tur , tur , tur , tur n off engine n off engine n off engine n off engine n off engine ,[...]

34 CARE AND MAINTENANCE ENGINE: For complete maintenance and operating information of the engine, please refer to the maintenance instructions furnished by the engine manufacturer and included in your Zero Turn Radius mower informa- tion packet. BATTERY: • This is a maintenance-free battery and the fluid level cannot be checked. • Charge batter[...]

35 CARE AND MAINTENANCE CUTTER BLADE MAINTENANCE: CAUTION Stop engine and remove ignition key for safety. Wear heavy, thick gloves when holding onto cutter blade, avoid the sharp edge of the blade. Check sharpness of mower blades after every 10 hours of operation. Observe proper blade position prior to removal. 1. Safely raise front of mower. 2. Ho[...]

36 CARE AND MAINTENANCE BELTS: Check belts every 50 hours. Replace any belts found to be in poor condition. BELT TENSION: Engine to Mower Deck Belt: P/N 6111 (42 & 50) P/N 6938 (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 additi[...]

37 LUBRICATION: CHASSIS: (5) grease zerks used LOCATIONS: (1) each front wheel caster tube (1) each mower deck hub SERVICE INTERVALS: Every 50 hours of operation RECOMMENDED GREASE: Name brand wheel bearing or multi-purpose grease. Once per season or 50 hours of operation (3 pumps each). Note: Adequate lubrication of the caster tubes and mower deck[...]

38 Hex Head Valve Stem Hot oil may cause burns. Allow engine to cool before draining oil. CAUTION CARE AND MAINTENANCE CHANGING THE ENGINE OIL: 1. The Dapco oil drain valve is located on the right side of the engine crankcase on the 5004 & 5005 and on the left side of the engine crank- case on the 5023. 2. Place a suitable container under[...]

39 CARE AND MAINTENANCE OIL FILL: 1. Drain oil. 2. Clean any spilled oil from engine and chassis. 3. Refill engine with type, and quantity of oil recommended by the engine manufacturer in engine literature. OIL FILTERS: 1. Replace filter each time the oil is changed. 2. These filters can be obtained from your authorized engine dealer. Kawasaki (P/N[...]

40 HYDROSTATIC TRANSMISSION OIL & FILTER SERVICE: If transmission is to be serviced, proper air purging procedures must be followed, or damage will occur. 1 . Remove oil filter from chassis allowing oil to drain into container. Clean impurities from inside of reservoir, if necessary. 2 . Fill new filter with oil (not doing so can cause air pock[...]

41 CARE AND MAINTENANCE HYDROSTATIC TRANSMISSION OIL & FILTER SERVICE (continued): 5 . Depress by-pass valve on both hydros. 6 . Start engine and move throttle to mid-range setting. 7 . Release parking brake. 8 . Dirty oil, filled with air bubbles, will start to drain from oil return hoses into container. When oil flowing from hoses is clear an[...]

42 CARE AND MAINTENANCE HYDROSTATIC TRANSMISSION OIL & FILTER SERVICE: Dirt or water in oil can ruin the hydrostatic transmissions. SERVICE INTERVALS: 1. Initial filter service - 50 hours 2. Every 250 hours or once a year thereafter. OIL REQUIREMENTS: Any high quality engine oil with an API classification of SG/CD is recommended. RECOMMENDED OI[...]

43 CARE AND MAINTENANCE ELECTRICAL SYSTEMS: Keep all connections clean and tight. CLEANING THE MOWER: Wash mower periodically. Clean above and below deck. High pressure washing and alkaline based soaps can cause damage to bearings and other parts of the mower. After washing your mower, start the engine and engage the mower deck for a few minutes to[...]

44 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 locknuts 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. Pl[...]

45 CARE AND MAINTENANCE MOWER DECK LEVELING PROCEDURE (continued): D . Turn both outer blades to align with the deck in front-to-rear manner. Turn left rear adjuster nut up or down until rear of mower deck is positioned level to 1/8 higher in the rear than the side-to-side measurement. At this time, the mower deck will be suspended o n (3) point[...]

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

47 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 free play or move- ment at a mid-point between the pulleys on the hydrostats and[...]

48 CARE AND MAINTENANCE PARKING BRAKE CABLE ADJUSTMENT: Make necessary adjustments to the T-Box to Hydrostat belt, as shown on page 47. 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. At this time, check that the cable has approx[...]

49 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 [...]

50 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 paking brake. 3. Raise the upper body to access hydro control linkage. If right wheel creeps, adjust right side linkage and v[...]

51 CARE AND MAINTENANCE NEUTRAL ADJUSTMENT(continued): 4. Engage parking brake and lower the body. Release parking brake and swing control levers in. If wheel creeps, repeat step 3. 5. Stop engine and remove rear of machine from jack or blocks. 6. Drive machine with both levers in top speed position. If one side now drives slightly faster than the [...]

52 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. The entire clutch must be repl[...]

53 CARE AND MAINTENANCE PROCEDURE FOR ELECTRIC CLUTCH ADJUSTMENT (CONTINUED): B. OHMS TEST 1. Disconnect clutch from mower wiring harness. 2. Attach the two leads on multi-meter to the two wires coming from the electric clutch. 3. The reading you receive should be between 2.5 to 4.0 OHMS. 4. If the resistance is outside this range, the clutch coil [...]

54 CARE AND MAINTENANCE FORWARD TRAVEL SPEED ADJUSTMENT: 1. Drive machine on a smooth surface with both levers in top speed position. 2. If one side 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 [...]

55 1 . ENGINE WONT TURN OVER Mower blades engaged- - - - - - - - - - - - - - - - - - - - - - -disengage blades Drive not in neutral - - - - - - -move control levers to neutral OUT Circuit breaker trips- - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - reset breaker Dead battery- - - - - - - - - - - - - - - - - - - - - - - - - -[...]

56 TROUBLESHOOTING 6. ENGINE RUNS BUT MOWER WONT MOVE FORWARD Drive belt broken or slipping- - - - - - - - - - - - - - - - - - - - replace drive belt Transmission oil low- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - -add oil Transmission locks in free-wheel position- - - - lock position( see pg.20) Hydrostat oil filter p[...]

57 STANDARD SERVICE PARTS LIST 42 Deck Blades: Hi-Lift - P/N 8688 (Standard) Lo-Lift - P/N 6236 Belts: Engine to Mower Deck - P/N 6111 Serpentine - P/N 6109 Engine to T-Box - P/N 7253 T-Box to Hydros - P/N 1765 Grass Blower Belt - P/N 4983 50 Deck Blades: Hi-Lift - P/N 9444 (Standard) Lo-Lift - P/N 9443 Belts: Engine to Mower Deck - P/N 6111 [...]

58 STANDARD SERVICE PARTS LIST KAWASAKI AND KOHLER AIR & OIL FILTER PART NUMBERS: Refer to engine manufacturers manual for correct service intervals for engine oil changes and air filter maintenance. Protect your engine investment, use only original equipment filters. Kawasaki (5004/5005) Air Filter Kit - P/N 79010 Engine Oil Filter - P/N 79009[...]

59 OWNER INFORMATION Date Purchased _ ________________________________ Mower Model Number ____________________________ Mower Serial Number ____________________________ Purchased From ___ _____________________________ Name ________________________________ Address ________________________________ DATE OIL CHANGED: DATE ENGINE TUNED: _________________[...]

ZTR®Mowers ZTR®Mowers ZTR®Mowers ZTR®Mowers ZTR®Mowers Dixon® and ZTR® are registered trademarks of Dixon Industries, Inc. DIXON INDUSTRIES, INC. a BLOUNT International Inc. Co. P.O. Box 1569 Coffeyville, Ks 67337-0945 620-251-2000 5000 Series 5004/5005/5023 Part No. 13634-0702 W W W W W ARNING: ARNING: ARNING: ARNING: ARNING: The engine exh[...]