Dixon ZTR 5422 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 manua l carefully and become completely familiar with the controls. The information in this operat[...]

Part No. 8965 September 1995 INDEX SAFETY ............................................................ Pages 1 - 6 WARRANTY POL ICY ......................................... Page 7 SPECIFICATIONS .............................................. Page 8 - 10 SEAT ADJUSTMENT ......................................... Page 11 CONTROLS ....................[...]

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[...]

SAFETY SAFETY SYMBOLS: SAFETY ALERT SYMBOL - When you see this symb ol, 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,[...]

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 al l instructions in the manual and on the mower before starting. * Only allow responsible adults, who are familiar with the[...]

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 with your Dixon ZTR - never up or down. Remove obstacle[...]

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 acti vity. 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 adul[...]

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 MODEL S 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 re sidential homeowner applications (us[...]

SPECIFICATIONS Model ZTR 5422 CHASSIS: 11 GA - rectangular tube BODY: Two piece - made of rotational molded polyethylene. Front body contains access panels for battery s ervice 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[...]

SPECIFICATIONS Model ZTR 5502 CHASSIS: 1 1 GA - rectangular tube BODY: Two piece - made of rotationa l 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 of high dens[...]

SPECIFICATIONS Model ZTR 5601 CHASSIS: 11 GA - rectangular tube BODY: Tw o 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: Ergonomically designed for operator co mfort by use of high dens[...]

SEAT ADJUSTMENT INSTRUCTIONS Models ZTR 5422 - ZTR 5502 - ZTR 5601 : 1. Place parking brake in ON position. (Pull brake lev er up) 2. Raise and push seat assembly and upper body rearward. 3. Loosen two front seat adjustment knobs, P/N 3978, and slide seat forward or backward to desired position. ~ 4. Re - tighten front seat adjustment knobs, P/N 39[...]

CONTROLS Page 12[...]

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 syste[...]

TO GO FORWARD: From neutral position, gent ly 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 t[...]

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)[...]

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 initi[...]

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 elect ric blade drive switch turned ON and parking brake in the ON position, engine should not turn over or attem[...]

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 s tarts, release ignition key. Key will return to "Run" position. 4. Once engine starts to warm up, slowly move chok[...]

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 retu rn to "Run" position. 3. Move throttle control lever to wide open or maximum setting for actual[...]

OPERATION INSTRUCTIONS M OWING 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 bes[...]

OPERATI ON 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 settin g. 2. Do Not Attempt To Cut Grass When It Is Wet. Wet grass will clog both the underside of t[...]

OPERATION INSTRUCTIONS SIDE DISCHARGE OF THE CLIPPING S: 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. CAUTION Be sure that deflector is properly installed on the discharge chute. 1. Set eng[...]

OPERATION INSTRUCTIONS DECK ROLLERS: Purpose: The spring loaded deck rollers 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 should prove ideal under m[...]

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 service situations can be handled by a Dixon ZTR dealer who is familiar with[...]

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 gl oves when holding onto cutter blade, avoid the sharp edge of the blade. NOTE: Be sure blade is centered on pilot before tightenin[...]

CARE AND MAINTENANCE - 5000 SERIES MODELS BELT TENSION ENGINE TO MOWER DEC K 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 P/N 1300 Model ZTR 5601 P/N 6938 Refer to illustration for adjustment procedure. NOTE: Belt defl ection or movement should be approxim[...]

CARE AND MAINTENANCE - 5000 SERIES MODELS FUEL SHUT OFF VALVE: A fuel shut off valve is located at the bo ttom 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 ground. Slopes are a major f actor related to loss - of - control and tip - over[...]

CARE AND MAINTENANCE - 5000 SERIES MODELS CAUTION HOT oil may cause burns. Allow engine to cool before draining oil. CHANGING THE ENG INE 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 [...]

CARE AND MAINTENANCE - 5000 SERIES MODELS MOWER DECK INSTALLATION: NOTE: B rake 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. REMOV E AND DISCARD cott[...]

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 d eck. 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 h[...]

CARE AND MAINTENANCE - 5000 SERIES MODELS Adjustment of the drive system is limited to the a ctual 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[...]

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 full y and apply tension to the belt. At this time, check that the cable which pulls the idler to a neutral position has approximately 1 - 1/2[...]

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 a djustment is required, loosen loc[...]

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 leve r stops on the bottom of each lever are hitting the stop blocks. If adjustment is required, loosen th[...]

CARE AND MAINTENANCE - 5000 SERIES MODELS PROCEDURE FOR ELECTRIC CLUTCH ADJUSTMENT Electric clutches require periodic Air Gap adjust ments 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 assembl[...]

CARE AND MAINTENANCE - 5000 SERIES MODELS HYDROST ATIC 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 OI L WEIGHT: Normal operation temperatures - 20 W 50 [...]

CARE AND MAINTENANCE - 5000 SERIES MODELS WHEELS AND TIRES: Correct tire pressure is important for correct operation of mower. Model ZTR 5422 Front Tires 11X4X4 Air Pressure 16 - 21 Ibs. Rear Tires 18 X 9.50 X 8 Air Pressure 8 - 14 Ibs. Models ZTR 5502 & ZTR 5601 Front Tires 11X4X5 Air Pressure 16 - 21 Ibs. Rear Tires 20 X 1 0 X 8 Air Pressure [...]

STANDARD SERVICE PARTS LIST MODEL ZTR 5422: BLADES: Standard: P/N 6236 Hi - Lift: P/N 8688 BELTS: Engine To Mo wer 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: BLADES: Standard: P/N 8689 Hi - Lift: P/N 9265 BELTS: Engine To Mower Deck: P/N 61 1 1 Serpe[...]

STANDARD SERVICE PARTS LIST KOHLER AIR AND OIL FILTER PART NUMBERS: Refer to engine manufacturers manual for recommendations regarding frequency of servic e required for engine oil changes and air filter maintenance. Protect your engine investment, use only original equipment filters. Model ZTR 5422: 16HP Pre - Cleaner Foam Element 45083 - 01 Cartr[...]

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 RPM and ground spe ed 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: t' - 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 o[...]

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 over Dead b attery 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 BLOUNT COMPANY AIRPORT INDUSTRIAL PARK PO BOX 1569 COFFEYVILLE KS 67337 O945 316 251 2OOO FAX 316 251 4117 OWNER INFORM ATION DATE PURCHASED MOWER MODEL NUMBER PURCHASED FROM Name Address MOWER SERIAL NUMBER DM - DATE OIL CHANGED: DATE ENGINE TUNED:[...]

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WARNI NG: 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 INDUSTRIES, INC. A BLOUNT C OM PAN Y AIRPORT INDUSTRIAL PARK PO BOX 1569 COFFEYVILLEKS 673370945 3162512000 FAX 316 2[...]