Dixon ZTR 5423 manual

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IMPORT ANT - READ C AREFULLY 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 ca refully and become completely familiar with the controls. The information in this oper[...]

Part No. 8965 September 1996 INDEX SAFETY ............................................................... Pages 1 - 6 WARRANTY POLICY .......................................... Page 7 SPE CIFICATIONS ............................................... Page 8 - 10 SEAT ADJUSTMENT ........................................... Page 11 CONTROLS .............[...]

RIDING LA WNMOWERS, IF IMPROPERLY OPERATED, CAN CAUSE SERIOUS INJURY OR DEATH The most common causes of injury to the operator or bystander... TIP - OVER RUN - OVER RUN - OVER Page 1 BLADE CONTACT[...]

SAFETY SYMBOLS: SAFETY ALERT SYM BOL - 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[...]

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 [...]

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 rocks,[...]

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 wh ere 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. • [...]

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 befo re refueling. Do not smoke. Never refuel the mower indoors. Never store the mower or fuel container inside a building where[...]

DIXON LIMITED WARRANTY POLICY -- HYDRO - GEAR MODELS This warranty policy applies to all HydroG ear 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 residential homeowner applications (use[...]

SPECIFICATIONS Model ZTR 5423 CHASSIS: 1 1 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: Design ed for operator comfort by use of high density closed cel[...]

SPECIFICATIONS Model ZTR 5502 CHASSIS: 1 1 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 rem oval. Rear body tilts up to allow service on the entire drive system. SEAT: Economically designed for operator comfort by use of high densi[...]

SPECIFICATIONS Model ZTR 5601 CHASSIS: 1 1 GA - rectangular tube BODY: Two piece - mad e 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: Ergonomically designed for operator comfort by use o f high den[...]

SE AT ADJUSTMENT INSTRUCTIONS Models ZTR 5423 - ZTR 5502 - ZTR 5601 : 1 . Place parking brake in ON position. (Pull brake lever up) 2. Raise and push seat assembly and upper body rearward. 3. Loosen two front seat adjustment knobs, P/N 3978, a nd slide seat forward or backward to desired position. 4. Re - tighten front seat adjustment knobs, P/N 39[...]

Page 12 CONTROLS[...]

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 . Do not leave engine running for extended periods of time without the parking brake engaged. Damage to the dr[...]

TO GO FORWARD: From neutral position, gently push both drive levers forward. To increase speed, move le vers 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 t[...]

CONTROLS BLADE DRIVE: Locat ed 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)[...]

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. During init[...]

OPERATION INSTRUCTIONS PARKING BR AKE 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. BL ADE 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 atte[...]

OPERATION INSTRUCTIONS STARTING INSTRUCTIONS: Cold Engine 1. Push cho ke 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. Once engine starts to warm up, slowly move choke[...]

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 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[...]

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 ti ps 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 41. Be sure that deflector is properly installed on the discharge chute . 1. Set engine spee[...]

OPERATION INSTRUCTIONS DECK ROLLERS: Purpose: The spring loaded deck r ollers located at the front corners of the 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 sh ould prove ideal under[...]

CARE AND MAINTENANCE - 5000 SERIES MODELS 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 se rvice situations can be handled by a Dixon ZTR dealer who is familiar wit[...]

CARE AND MAINTENANCE - 5000 SERIES MODELS CUTTER BLADE MAINTENANCE: NOTE: Observe proper blade positio n prior to removal. 1. Safely raise front of mower. 2. Hold or block blade from turning. 3. Loosen blade nut and remove blade. Wear heavy, thick gloves when holding onto cutter blade, avoid the sharp edge of the blade. 4. Tighten blade nut securel[...]

CARE AND MAINTENANCE - 5000 SERIES MODELS NOTE: Be sure blade is centered on pilot be fore tightening bolt to 60 ft. l bs. torque. BELT TENSION ENGINE TO MOWER DECK BELT: Models ZTR 5423 & ZTR 5502 P/N 6111 Model ZTR 5601 P/N 693 9 The engine to mower deck drive belts are automatically held in proper tension by springs which push the deck assem[...]

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. LUBRICATION CHASSIS: Number of grease zerks used: (7) LOCATIONS: (1) each front wheel caster and each front wheel hub (1) [...]

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 groun d. Slopes are a major factor related to loss - of - control and tip - over[...]

CARE AND MAINTENANCE - 5000 SERIES MODELS HOT oil may cause burns. Allow engine to cool before draining oil. CHANGING THE ENGIN E 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 fitting of a short piece of hose to the valve will help dire[...]

CARE AND MAINTENANCE - 5000 SERIES MODELS MOWER DECK INSTALLATION: NOTE: Brake link (P/N 5283) normally used for installation of engine to mower dec k 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. REMOVE AND DISCARD cotte[...]

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. Deck should be level o r pitched slightly h[...]

CARE AND MAINTENANCE - 5000 SERIES MODELS Adjustment of t he 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 movemen t at a mid - point between th[...]

CARE AND MAINTENANCE - 5000 SERIES MODELS PARKING BRAKE CABLE ADJUSTMEN T: 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 which pulls the idler to a neutral position has a pproximately 1 - 1/[...]

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. If adjustment is required, loosen lock [...]

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. If adjustment is required, loosen the[...]

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[...]

CARE AND MAINTENANCE - 5000 SERIES MODELS HYDROSTATIC TRANSMISSION OIL AND FILTER SERVICE SERVICE INTERVALS: 1. Initial oil and filter service - 50 hours. 2. Ev ery 250 hours thereafter. OIL REQUIREMENTS: Any high quality engine oil with an API classification of SG/CC is recommended. RECOMMENDED OIL WEIGHT: Normal operation temperatures - 20 W 50 C[...]

CARE AND MAINTENANCE - 5000 SERIES MODELS WHEELS AND TIRES: Correct tire pressure is i mportant for correct operation of mower. Model ZTR 5423 Front Tires 11X4X4 Air Pressure 16 - 21 Ibs. Rear Tires 1 8 X 9.50 X 8 Air Pressure 8 - 1 4 Ibs. Models ZTR 5502 & ZTR 5601 Front Tires 11X4X5 Air Pressure 16 - 21 Ibs. Rear Tires 20 X 10 X 8 Air Pressur[...]

ST ANDARD SERVICE PARTS LIST MODEL ZTR 5423: BLADES: Standard: Hi - Lift: P/N 6236 P/N 8688 BELTS: Engine To Mower Deck: Serpentine Belt: Engine To T - Box: T - Box To Hydros: Grass Blower Belt: - P/N 6111 P/N 6109 P /N 1714 P/N 1765 P/N 4983 MODEL ZTR 5502: BLADES: Standard: Hi - Lift: P/N 9443 P /N 9444 BELTS: Engine To Mower Deck: Serpentine Bel[...]

ST AN DARD 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 equipme nt filters. Model ZTR 5423: 18HP Pre - Cleaner Foam Element Cartridge Air [...]

TROUBLESHOOTING MOWER CUT QUALITY: There are many variables that can effect the cut quality of any riding mower. Type and conditions of grass, cut height setting, engine RP M 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 DRIV E SYSTEM: SITUATION CAUSES REMEDY Mower pulls to one side or the other Drive adjustment 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 transmissions are "air locked", low or no oil [...]

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

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Dixon Industries, Inc. A International, Inc. Company P.O. Box 1569 Coffeyville, KS 67337 - 0945 316 - 251 - 2000 OWNER INFORMATION DATE PURCHASED MO WER MODEL NUMBER PURCHASED FROM Name Address MOWER SERIAL NUMBER DM - DATE OIL CHANGED: DATE ENGINE TUNED:[...]

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The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. ® Dixon and ZTR are registered trademarks of Dixon Industries, Inc. Dixon I ndustries, Inc. A BLOUNT International, Inc. Company P.O.Box 1569 Coffeyville, KS 67337 - 0945 316 - 251 - 2000 Part No. 8965[...]