Dixon Lawn Mower 13089 0601 User Guide

5000 SERIES  
ZTR®  
2002  
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INDEX  
Page  
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11  
Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-14  
Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . . . . . . . .15  
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-20  
Operation Instructions. . . . . . . . . . . . . . . . . . . 21-32  
Care & Maintenance. . . . . . . . . . . . . . . . . . . . . .33-54  
Standard Service Parts List. . . . . . . . . . . . . . . . . . . .55  
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 56-57  
5000 Series  
Part No. 13089-0601  
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SAFETY  
RIDING LAWN MOWERS,  
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  
BACK OVER  
...read and understand this manual to prevent injuries.  
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SAFETY  
Safety Alert Symbol  
When you see this symbol,  
BE ALERT to the potential for injury.  
Follow recommended safety precautions  
and safe operating practices.  
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  
serious injury.  
CAUTION  
(highlighted in yellow)  
indicates a potentially  
hazardous situation which, if not  
avoided, may result in minor or  
moderate injury. It may also be used  
to alert against unsafe practices.  
5
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SAFETY  
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 rocks, toys, wire, etc.,  
which could be picked up and thrown by the blade.  
•Be sure the area is clear of other people before mowing.  
Stop mower if anyone enters the area.  
•NEVER carry passengers.  
•Do not mow in reverse unless absolutely necessary. Always  
look down and behind before and while backing.  
•Be aware of the mower discharge direction and do not point  
it at anyone.  
•Do not operate the mower without either the entire grass  
catcher or the deflector in place.  
•Slow down before turning.  
•Never leave a running mower unattended. Always turn off  
blades, set parking brake, stop engine and remove key before  
dismounting.  
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SAFETY  
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 crossingroadways.  
•Use extra care when loading or unloading the mower into a  
trailer or truck. Do not ride the mower when loading and  
unloading.  
•Always wear safety goggles or safety glasses with side  
shields when operating mower.  
•Data indicates that operators, age 60 years and above, are  
involved in a large percentage of riding mower-related  
injuries. These operators should evaluate their ability to  
operate the riding mower safely enough to protect  
themselves and others from serious injury.  
•Follow the manufacturers recommendation for wheel  
weights and counterweights.  
Maintain or replace safety & instruction labels as needed.  
The engine exhaust from this product contains chemicals known to the  
WARNING:  
State of California to cause cancer, birth defects or other reproductive  
harm.  
7
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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 obstacles such as rocks, tree limbs, etc.  
Watch for holes, ruts or bumps. Uneven terrain could overturn the  
mower. Tall grass can hide obstacles.  
Use slow speed. Tires may lose traction on slopes even though the  
brakes are functioning properly.  
Use extra care with grass catchers or other attachments. These can  
change the stability of the mower.  
Keep all movement on the slopes slow and gradual. Do not make  
sudden changes in speed or direction.  
Avoid starting or stopping on a slope. If tires lose traction, disengage  
the blades and proceed slowly down the slope.  
If front wheels lift off the ground, pull the levers back to stabilize the  
mower.  
DO NOT  
Do not turn on slopes unless necessary, and then, turn slowly and  
gradually downhill, if possible.  
Do not mow near drop-offs, ditches, or embankments. The mower  
could suddenly turn over if a wheel is over the edge of a cliff or ditch,  
or if an edge caves in.  
Do not mow on wet grass. Reduced traction could cause sliding.  
Do not try to stabilize the mower by putting your foot on the ground.  
Do not use grass catcher on steep slopes.  
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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.  
Be alert and turn mower off if a child enters the area.  
Before and during backing, look BEHIND and DOWN for  
small children.  
Never carry children. They may fall off and be seriously  
injured or interfere with safe mower operation.  
Never allow children to operate the mower.  
Use extra care when approaching blind corners, shrubs,  
trees, or other objects that may obscure vision.  
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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 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 building  
where there is an open flame.  
If fuel is spilled on clothing, change clothing immediately.  
To prevent fire and explosion caused by static electricity:  
Never fill containers inside a vehicle or on a truck  
or trailer bed with a plastic liner. Always place  
containers on the ground away from your vehicle  
before filling.  
When practical, remove fuel-powered equipment  
from the truck or trailer and refuel it on the  
ground. If this is not possible, then refuel such  
equipment on a trailer with a portable container,  
rather than from a fuel dispenser nozzle.  
If a fuel dispenser nozzle must be used, keep the  
nozzle in contact with the rim of the fuel tank or  
container opening at all times until fueling is  
complete. Do not use a nozzle lock-open device.  
10  
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SAFETY  
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 oil or fuel spillage. Allow mower to cool before storing.  
Stop and inspect the equipment if you strike an object. Repair,  
if necessary, before restarting.  
Never make adjustments or repairs with the engine running  
unless otherwise specified.  
Grass catcher components are subject to wear, damage and  
deterioration, which could expose moving parts or allow objects  
to be thrown. Frequently check components and replace with  
original equipment parts, when necessary.  
Mower blades are sharp and can cut. Wrap the blade(s) or wear  
gloves, and use extra caution when servicing them.  
Batteries contain sulfuric acid. To prevent burns avoid contact  
with skin, eyes and clothing. To prevent a fire or explosion keep  
sparks and open flames away from battery.  
Before disconnecting the negative (-) ground cable, make sure all  
switches are OFF.  
11  
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DIXON INDUSTRIES, INC.  
a BLOUNT company  
Airport Industrial Park  
P.O. Box 1569  
Coffeyville, Ks 67337- 0945  
620-251-2000  
Fax 620-251-4117  
DIXON LIMITED WARRANTY POLICY - ESTATE MODELS  
5000 Series  
WARRANTY: Home Owner Application: This Dixon Warranty term is for a period of two (2)years  
from date of purchase. Commercial Application: Dixon mowers used for commercial application  
are warranted for one (1) year from the date of purchase or 400 hours whichever comes first.  
Commercial use is specified as use other than, or in addition to, mowing at owners primary  
place of residence.  
DIXON ZTR MOWERS ARE WARRANTED AGAINST DEFECTS IN MATERIALS  
AND WORKMANSHIP AND PROVIDES FOR REPLACEMENT OR REPAIR  
OF PARTS INCLUDING LABOR COSTS. THIS WARRANTY IS SUBJECT  
TO THE FOLLOWING CONDITIONS AND LIMITATIONS:  
1. Warranty applies only to original retail purchaser of new & unused mowers and accessories.  
2. All Dixon warranty must be accomplished by authorized Dixon dealers and in accordance with Dixon  
warranty policy and allowances. All warranty claims must be approved by Dixon Industries, Inc.  
3. Battery warranty: Limited to 90 days from date of purchase.  
4. Accessories Warranty (Grass Catchers, Snow Blades, Covers, etc.): Limited to 90 days from date of  
purchase.  
5. Warranty does not apply to damage in transit or incidents of misuse, negligence, accidents, or  
alteration. The use of parts or components other than those supplied by Dixon Industries,  
Inc. VOIDS ALL WARRANTY.  
6. The following items are not covered by this warranty policy:  
a.  
Pick up and delivery charges for transportation of mower to and from an authorized Dixon  
dealers place of business.  
b.  
c.  
d.  
Routine maintenance or adjustments.  
Belts/ cutting blades/ Hydro-Gear filters.  
Engines - All engines used on Dixon ZTR mowers are warranted by the individual engine  
manufacturer.  
Any costs or expense of providing substitute equipment while repair work is being  
performed on a warranted mower.  
e.  
7. There is no other express warranty. Implied warranties, including those of merchantability and fitness  
for a particular purpose, are limited to the same duration of the express warranty, and to  
the extent permitted by law any and all implied warranties are excluded. Liabilities for  
consequential damages under any and all warranties are excluded.  
Blue/ Customer  
Yellow/ Dealer  
White/ Dixon Ind.  
WARRANTY VALIDATION: At the time of sale, selling dealer must review each portion of this  
warranty document, complete the information section below, secure customers signature and  
send copy to Dixon Industries, Inc.  
DATE OF PURCHASE____________________MODEL___________________S/ N_______________  
_____________________________________  
Owners Name  
______________________________________  
Dealership  
_____________________________________  
Address  
______________________________________  
Address  
______________________________________  
_______________________________________  
_____________________________  
______________________________  
Owners Signature  
Dealers Signature  
12  
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SPECIFICATIONS  
Model ZTR 5020  
CHASSIS:  
BODY:  
11 GA - rectangular tube  
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  
closed cell foam padded back rest and arm rests,  
upholstered with CorduraTM water-repellent fabric. Seat  
is adjustable fore and aft.  
MOWER DECK:  
Two decks are available. The 60” is made of stamped  
steel. The 50” is made of 11 GA fabricated welded  
construction with external reinforcement ribs. Three  
blades combine for either a 50” or 60” cut width. Cut  
height approximately 1.5” to 4.5via 7 position lift handle.  
BLADE DRIVE:  
Electric clutch  
DRIVE SYSTEM:  
Each rear wheel is independently driven by a HydroGear  
BDU-10L Series 70 hydrostatic transmission. The hydrostatic  
transmissions power a fully enclosed HydroGear gearbox.  
ENGINE:  
20HP Briggs & Stratton ELS, overhead valves, replaceable  
oil filter, full pressure lube system, dual element air cleaner,  
integral fuel pump.  
STARTING SYSTEM: Electric by key switch operation with safety interlocks on  
parking brake and blade drive clutch.  
TIRES:  
Front  
Rear  
11 X 4-5 ribbed tread  
20 X 10-8 Multi-Trac  
RECOMMENDED  
TIRE PRESSURE:  
Front  
Rear  
16 - 21 lbs.  
8 - 14 lbs.  
CAPACITIES:  
Fuel - 4.8 gallons total (dual tanks)  
Oil tank - 3 quart with in-line 40 micron filter  
Engine - 2 qts. SAE 30 (with filter)  
DIMENSIONS:  
Width  
60” (50” Deck), 73” (60” Deck)  
Height  
Length  
Weight  
45”  
72:  
668 lbs, (50” Deck, 685 lbs (60” Deck)  
Additional information provided in service instructions under the individual component.  
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE  
13  
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SPECIFICATIONS  
Model ZTR 5023  
11 GA - rectangular tube  
CHASSIS:  
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  
foam padded back and arm rests, upholstered with CorduraTM  
water-repellent fabric. Seat is adjustable fore and aft.  
MOWERDECK:  
Two decks are available. The 60" is made of stamped steel. The  
50" is made of 11 GA fabricated welded construction with external  
reinforcement ribs. Three blades combine for a 50" or 60" cut  
width. Cut height approximately 1.5" to 4.5" via 7 position lift  
handle.  
BLADEDRIVE:  
Electric clutch  
DRIVE SYSTEM:  
Each rear wheel is independently driven by a HydroGear BDU-10L  
Series 70 hydrostatic transmission.The hydrostatic  
transmissions, in turn, power a fully enclosed HydroGear gearbox.  
ENGINE:  
23HP Kohler Command, 4-Cycle, V-Configuration, Overhead Valve,  
Air-Cooled, Gasoline, Vertical Shaft, Aluminum Head, and Crankcase  
with Cast Iron Liners, Full Pressure Lubrication/ Full Flow Filter,  
Pulse-type Fuel Pump, Fixed Jet Carburetor w/ Smart-Choke,  
Electronic Ignition, In-Line Fuel Filter, Dual Element Air Cleaner.  
STARTINGSYSTEM:  
TIRES:  
Electric by key switch operation with safety interlocks on parking  
brake and blade drive clutch.  
Front  
Rear  
11 X 4-5 Ribbed Tread  
20 X 10-8 Multi Trac  
RECOMMENDED  
TIREPRESSURE:  
Front  
Rear  
16 - 21 lbs.  
8 - 14 lbs.  
CAPACITIES:  
Fuel - 4.8 gallons total (dual tanks)  
Hydrostat oil tank - 3 quart with in-line 40 micron filter  
Engine - 2 qts. SAE 10W30 (with filter)  
DIMENSIONS:  
Width  
Height 45"  
60"(50" Deck), 72"(60" Deck)  
Length 72"  
Weight 680 lbs.(50" Deck), 685 lbs.(60" Deck)  
Additional information provided in service instructions under the individual component.  
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTIFICATION  
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SEAT ADJUSTMENT INSTRUCTIONS  
5000 Series Models  
1 .  
Grasp seat slide adjuster and move  
it into adjustment position.  
2 .  
3 .  
Slide seat forward or backward.  
Release seat slide adjuster.  
15  
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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:  
Turning is controlled by moving one control lever slightly forward or  
rearward of the other.  
To turn left, move left lever rearward of the right lever.  
To turn right, move right lever rearward of the left lever.  
To turn on mowers own axis (zero turning radius), stop and move one  
lever to reverse position and the other to forward position.  
BRAKING:  
To brake mower, move both levers in direction opposite of travel.  
LEFT TURN OPPOSITE  
Note: The pressure required to operate the mower is very light.  
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CONTROLS  
CHOKE CONTROL LEVER:  
Located on control panel to operators right.  
Used to start a cold engine.  
THROTTLE CONTROL LEVER:  
Located on control panel to operators 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 the engine and to maintain  
mower deck blade speed.  
17  
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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).  
To release brake, move lever forward  
(down).  
Note: Always set parking brake  
before dismounting. Release  
parking brake before moving  
mower.  
HYDRO GEAR SYSTEM:  
Allows the mower to turn on its own  
axis (zero turning radius).  
Each lever controls one side of the  
mower.  
Note: The pressure required to operate  
the mower is very light.  
18  
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CONTROLS  
BLADE DRIVE:  
Located on control panel to  
operators right.  
To engage blade: Pull up on switch.  
To disengage blade: Push down.  
CIRCUIT BREAKER:  
Located on control panel to  
operators right.  
Protection of the electrical system  
is by (1) 15 amp circuit breaker.  
If circuit breaker trips, push button  
to reset.  
If this condition repeats, consult  
dealer for inspection and repair.  
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.  
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CONTROLS  
TO FREEWHEEL MACHINE (UNLOCK TRANSMISSION):  
Move end of by-pass keepers to depress plunger at rear  
of each hydro pump. Release parking brake.  
To engage the transmission, move by-pass keepers so  
plungers return to their normal positions.  
NOTE: Before pushing or towing tractor, transmission  
must be unlocked, and parking brake released.  
The tractor should never be pulled at more than  
2 miles per hour or for any appreciable distance.  
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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 initial operation, learning to drive, set  
throttle at slow speed.  
TOWING:  
Towing a trailer or other attachment that is too  
heavy could damage the drive or cause the mower  
to become unstable. Limit loads to 500 pounds  
or less with this mower.  
21  
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OPERATION INSTRUCTIONS  
BEFORE OPERATING MOWER:  
1.  
Read and observe all safety instructions on your  
mower and in the manual.  
2.  
Read engine manufacturers operating and  
maintenance instructions.  
3.  
4.  
5.  
6.  
7.  
8.  
Discuss proper maintenance with your dealer.  
Check engine oil.  
Check fuel cap to be sure it is in place.  
Be sure parking brake is on.  
Be sure mower blade drive is off.  
Know how to stop engine. (Turn key to off position).  
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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) Engage blade drive switch.  
c) Turn ignition switch to START.  
ENGINE SHOULD NOT TURN OVER  
OR ATTEMPT TO START!  
SEAT SWITCH TEST:  
a) In a SAFE AREA away from bystanders,  
start the engine.  
b) Engage blade drive switch.  
c) Raise slightly off seat.  
ENGINE SHOULD STOP!  
If any safety check fails: Do not operate the mower  
until the system has been checked and repaired  
by an authorized Dixon ZTR dealer!  
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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,  
2.  
Set engine speed control to the wide open or full  
setting.  
Do Not Attempt To Cut Grass When It Is Wet.  
Wet grass will clog the underside of the deck  
and discharge area.  
3.  
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.  
4.  
5.  
Keep The Underside Of The Mower Deck Clean.  
Frequent removal of dried grass and dirt will  
allow the clippings to discharge correctly.  
Maintain Sharp Blade(s) Throughout The Cutting  
Season.  
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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.  
Keep the underside of the mower deck clean.  
Maintain sharp blades throughout the cutting season.  
As a rule of thumb, never cut off more than 1/ 3 of the total  
grass blade length.  
Correct mowing height can reduce weeds and disease by  
50% to 80%.  
The following grass cut heights are based on adequate  
moisture conditions and normal thatch build-up in a healthy  
lawn. Some locations and applications may require slightly  
different cut heights. If in doubt, consult your local lawn  
professional for assistance.  
Grass Types  
Bermudagrass  
Bluegrass  
Best Cut Heights  
1 - 2”  
2 - 3”  
Buffalograss  
Ryegrass  
11/ 2 -3”  
2 - 3”  
Tall Fescue  
Zoysiagrass  
3-31/ 2  
1 - 3”  
25  
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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.  
Note: Model 5023 may  
require partial choke  
setting to start even if  
the engine has been  
operated for a period  
of time.  
4.  
Engine must be operated with  
throttle control in the fast”  
position, or maximum setting  
to insure adequate lubrication  
and cooling of the engine, and  
cut quality of the mower deck.  
26  
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OPERATION INSTRUCTIONS  
STARTING INSTRUCTIONS  
(cold engine):  
1.  
2.  
3.  
Position choke control in “on”  
position.  
Position throttle control at  
1/ 2 speed setting.  
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  
control to off” position.  
5.  
6.  
Move throttle control to the  
“fast” position.  
Engine must be operated  
with throttle control in the  
“fast” position, or maximum  
setting to insure adequate  
lubrication and cooling of the  
engine, and cut quality of the  
mower deck.  
CAUTION  
Do not operate the engine in an enclosed area  
due to the harmful exhaust gas produced.  
27  
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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 results, please read and follow the  
mulching tips listed below:  
1.  
Set the engine speed control to the wide open  
or full setting.  
2.  
Place the mower deck cut height selector in  
either the top or second notch. Never cut more  
than 3/ 4” to 1” off the grass at any one time.  
Attempting to cut more grass will result in the  
deck plugging and cause the engine to stall.  
3.  
It may be necessary to cut the lawn twice to  
achieve acceptable mulching performance  
especially on first cuttings or if the lawn is  
heavily fertilized.  
4.  
5.  
Do Not Attempt To Cut Grass When It Is Wet.  
Mulching performance will be very poor under  
wet grass conditions.  
Maintain Sharp Blade(s) Throughout The Cutting  
Season. This is very important. Optimal mulching  
performance cannot be obtained with a dull or  
nicked-up blade.  
28  
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OPERATION INSTRUCTIONS  
MOWING WITH A MULCHING ATTACHMENT  
(continued):  
6.  
7.  
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.  
Alternate mower direction. This will evenly  
disperse the mulched grass clippings over the  
lawn for even fertilization.  
If the mulching quality of the mower does not seem to be satisfactory,  
try one or more of the following tips:  
1.  
2.  
3.  
4.  
5.  
6.  
Raise the height-of-cut setting on your  
mower.  
It may be necessary to cut your grass  
more frequently.  
Operate the mower at a slower ground  
speed.  
Overlap cutting swaths instead of cutting  
a full swath with each pass.  
Mow across the marginal areas a second  
time.  
CUT HIGH - MOW OFTEN!  
29  
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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.  
2.  
3.  
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.  
Do Not Attempt To Cut Grass When It Is Wet.  
Wet grass will clog both the underside of the  
deck and the attachment chutes. Empty bags  
often to prevent plugging.  
If the grass is tall, place the mower deck cut  
height selector in the top or second notch.  
“Initially” overlap cutting swaths instead of a  
full swath with each pass.  
4.  
5.  
Keep The Underside Of The Mower Deck Clean.  
Frequent removal of dried grass and dirt will  
greatly assist in bagging of the clippings.  
Use only the correct blade(s). Some grass  
catching attachments require a high-lift blade.  
See your dealer for advice on the type of blade(s)  
needed for your mower.  
6.  
Maintain Sharp Blade(s) Throughout The Cutting  
Season.  
30  
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OPERATION INSTRUCTIONS  
MOWING WITH A GRASS CATCHER ATTACHMENT  
(continued):  
7.  
8.  
Operate the mower at a slower ground speed than  
when mowing without a grass catching attachment.  
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 with your dealer for more information  
regarding installation and adding weight to the box.  
CAUTION  
Watch for low hanging branches or other obstacles  
which might hit the catcher top while turning or  
backing the mower.  
Use care when backing to avoid pushing the grass  
bags into the frame or hot” exhaust muffler of the  
engine.  
Disengage blade and stop engine prior to clearing  
grass from either the discharge chute or grass  
catcher components.  
Keep all attachment bolts tight.  
Do Not operate the mower with the grass catching  
attachment partially removed.  
Important:  
Do Not leave clippings in the bags while  
the mower is stored.  
Damp grass clippings are a fire hazard  
if left in the bag.  
31  
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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.  
Normal height settings as installed at  
the factory allows each roller to ride  
slightly above the turf. This setting  
should prove ideal under most mowing  
conditions.  
Height:  
Adjustment: Some mowing applications may require  
lowering of each front roller. To lower  
the roller, remove the pin, spring,  
washers and spacer (P/ N 9789) from  
the top of roller bracket tube. Remove  
roller bracket from tube. Slide spacer  
P/ N 9789 on roller bracket shaft and  
reassemble using washer, spring and  
pin at the top.  
Lubrication: The use of a penetrating oil or light  
grease on the roller bracket shafts  
will keep roller moving freely.  
32  
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CARE AND MAINTENANCE  
CAUTION  
Before performing any maintenance, turn off engine,  
allow to cool & remove key.  
Use extreme care when working on machinery.  
Do not wear watch or jewelry. Do not wear loose fitting clothes,  
and observe all common safety practices with tools.  
MAINTENANCE SCHEDULE  
Adjust traction drive idler........................................after 5 hours break-in  
Check deck serpentine belt...........................................after 2 0 hours break-in  
(adjust bumper to approximately 1/ 2” thick)  
Check crankcase oil level..........................................................before each use  
Clean grass from hydrostat fans...........................................before each use  
Clean grass & debris from muffler & manifold area..........before each use  
Clean grass under deck...............................................................after each use  
Check tire pressure......................................................................every 1 0 hours  
Inspect blades for sharpness......................................................every 1 0 hours  
Check hydrostatic transmission fluid...........................................every 2 5 hours  
Clean air filter element....................................................................every 2 5 hours  
Check traction drive idler adjustment................................every 50 hours (see page 48)  
Grease all zerks.....................................................................................every 50 hours  
Check all belts..........................................................................................every 50 hours  
Change engine crankcase oil and filter...........(5 hours break-in) every 50 hours  
Replace air filter elements..........................................annually or every 100 hours  
Replace spark plugs.....................................................annually or every 100 hours  
Change hydrostat oil and oil filter................(100 hours break-in) every 500 hours  
33  
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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:  
Battery contains sulfuric acid electrolyte which is  
poisonous and corrosive.  
CAUTION  
This is a maintenance-free battery and the fluid level cannot  
be checked.  
Charge battery if required.  
OFF SEASON BATTERY STORAGE:  
DO NOT remove battery from mower.  
Clean top of battery and terminals with baking soda and  
water.  
Identify each cable so they can be reconnected to the  
correct terminal.  
Disconnect cables from terminals. ALWAYS disconnect  
ground cable first and reconnect last.  
Charge battery.  
TIRES:  
Correct tire pressure is essential for efficient operation of the  
mower. Check tire pressure periodically. Inflate tires to the  
pressure listed below.  
Front Tires  
Rear Tires  
11 x 4.00-5 16-21 lbs. PSI  
20 x 10.50-8 8-14 lbs. PSI  
Lug nuts or lug bolts should be checked regularly for tightness.  
34  
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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.  
2.  
Safely raise front of mower.  
Hold or block blade from  
turning.  
3.  
4.  
Loosen blade nut and  
remove blade.  
When replacing blade,  
tighten blade nut securely.  
Refer to diagram. Be sure  
blade is centered on pilot  
before tightening nut to 60  
ft. lbs.  
Blades should be discarded when worn excessively.  
DANGEROUS!  
DO NOT USE  
BLADE IN  
THIS  
New Blade  
CONDITION!  
When notch starts,  
discard blade  
35  
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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 (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 additional adjustment to be  
made.  
Mower Deck Serpentine Belt: P/ N 1300 (50)  
P/ N 6939 (60)  
Refer to illustration for adjustment procedure.  
Idler Weldment  
Idler Shock Mount  
“L” Rod  
Hex Nut  
5 / 8 ”  
Tighten or  
loosen hex  
nut to  
achieve this  
demension  
Note: Belt deflection or movement should be approximately 1/ 4” when  
measured at mid-point between pulleys. Periodically inspect both belt  
and idler systems.  
36  
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CARE AND MAINTENANCE  
FUEL SHUT OFF VALVE:  
The fuel shut off valve is located at the bottom rear of the  
fuel tank.  
Always turn the valve to the OFF” position when the mower  
is stored or not in use.  
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  
hubs will help dispel moisture from within the bearing  
retention areas. Bearings are of a sealed variety.  
37  
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CARE AND MAINTENANCE  
Hot oil may cause burns. Allow  
CAUTION  
engine to cool before draining oil.  
CHANGING THE ENGINE OIL:  
1.  
2.  
The Dapco” oil drain valve is located on the left  
side of the engine crankcase.  
Place a suitable container under the drain valve.  
The fitting of a short piece of hose will help direct  
the oil.  
3.  
To drain, turn hex head valve stem counter--  
clockwise with 10mm wrench or socket. Open  
to full open (approximately 7 turns).  
4.  
After engine is drained, tighten hex stem.  
NOTE: Refer to engine manufacturers recommendations  
for frequency of oil changes.  
Hex Head Valve Stem  
38  
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CARE AND MAINTENANCE  
OIL FILL:  
1.  
2.  
3.  
Drain oil.  
Clean any spilled oil from engine and chassis.  
Refill engine with type, and quantity of oil  
recommended by the engine manufacturer in  
engine literature.  
OIL FILTERS:  
1.  
2.  
Replace filter each time the oil is changed.  
These filters can be obtained from your  
authorized engine dealer.  
Briggs & Stratton (P/ N 492 932)  
Kohler (P/ N 12-050-01-5).  
3.  
The use of any other oil filter may cause damage  
to the engine.  
PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS.  
PROTECT YOUR ENVIRONMENT.  
39  
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CARE AND MAINTENANCE  
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 pocket in system and possible  
hydro damage). Install new oil filter to  
chassis. Use only genuine Dixon  
replacement oil filter. (Using any other  
brand of oil filter may not be internally  
compatible and could cause damage to  
hydrostat transmission.)  
3 .  
4 .  
Put fresh oil in reservoir. Fill reservoir  
to full mark.  
Remove two oil return hoses from top  
of oil reservoir and direct these hoses  
into a container for oil draining.  
40  
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CARE AND MAINTENANCE  
HYDROSTATIC TRANSMISSION OIL & FILTER SERVICE  
(continued):  
5 .  
6 .  
Depress by-pass valve on both hydros.  
Start engine and move throttle to  
mid-range setting.  
7 .  
8 .  
Release parking brake.  
Dirty oil, filled with air bubbles, will  
start to drain from oil return hoses  
into container. When oil flowing from  
hoses is clear and contains no  
bubbles, stop the engine.  
9 .  
Re-attach oil return hoses to top of  
reservoir.  
1 0 . Release by-pass valve on both hydros.  
1 1 . Add sufficient oil to reservoir to  
return oil level to full mark.  
41  
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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 OIL WEIGHT:  
Normal operation temperatures - 20W50  
Cold climate usage - 10W40  
Another alternative that will provide excellent all-  
climate performance and extended time between  
oil changes is a 15W50 synthetic engine oil.  
OIL FILTER:  
P/ N 7252 - IMPORTANT  
The oil filter is a special design for use on vacuum  
or suction” oil flow systems.  
DO NOT:  
Use automotive engine oil filters. These filters  
require a pressure” to allow oil flow. Usage will  
result in an air-lock” condition with possible  
damage.  
42  
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CARE AND MAINTENANCE  
ELECTRICAL SYSTEMS:  
Keep all connections clean and tight.  
CLEANING THE MOWER:  
Wash mower periodically. Clean above and below deck.  
Note: Allow mower to cool before washing. If bearings  
are hot, they will draw moisture inside as they  
dry and cause corrosion.  
SERIAL NUMBERS:  
The serial number is located on frame at rear of engine.  
WARRANTY:  
See Warranty Registration Form-P/ N 8288  
(sample on page 12).  
PARTS/ SERVICE:  
See your Dixon dealer for replacement parts, warranty or  
service.  
PLEASE HELP PROTECT THE ENVIRONMENT BY AVOIDING ALL  
CHEMCIALS WHICH MAY DAMAGE OR CAUSE HARM TO  
PLANTS AND ANIMALS IN YOUR AREA.  
43  
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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. Place the mower on a smooth level  
surface, check tire pressures to insure  
the mower has a correct stance. Inflate  
tires as required:  
Front: 16 - 21 lbs maximum  
Rear : 8 -14 lbs maximum  
NOTE: To insure accuracy of leveling  
procedure, mower deck drive belt must be  
installed prior to leveling deck.  
B. Wear heavy gloves. Turn each outer blade  
tip to align with the deck or in a side-to-side  
manner.  
C. Measure from the floor surface up to the  
bottom of the blade tip on the discharge  
side of the mower deck. Retain this  
measurement. Move to the opposite side,  
check that measurement is the same. If  
adjustment is required, turn the nut on the  
bottom of the front threaded adjuster up or  
down until both side-to-side measurements  
are equal. Retain measurement.  
44  
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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  
on (3) points (both front adjusters and the  
left rear adjuster). Move the right rear  
adjuster and take out the slack which will be  
present by turning adjuster locknut up.  
E. Confirm measurements once again. Blade  
tips should be level in a side-to-side manner.  
In the rear, blade tips should be level to 1/ 8"  
higher than side-to-side measurement. In  
the front, blade tips should be level to 1/ 8"  
lower than side-to-side measurement.  
NOTE: This will place the mower deck in a  
base measurement position. Additional  
adjustment may be required to achieve  
desired cut for the type of grass or  
conditions being mowed.  
Front  
Adjusters  
Left Rear  
Adjuster  
Deck Leveling Adjustment Points  
45  
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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.  
Insert end of  
link here  
5 2 8 3  
Link  
Front of  
lift frame  
2.  
Remove front and rear deck hanger pins, as  
illustrated below.  
3.  
4.  
Slide deck from beneath chassis.  
Reverse procedure to re-install deck to chassis.  
46  
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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 T-Box.  
Each hydrostat has a bypass relief pin located at the  
rear of the hydrostatic unit. A bypass keeper is  
provided to allow the mower to be rolled around without  
engine running. To accomplish this, the bypass keeper  
spring must be positioned to depress the bypass relief  
pins. Remove bypass keeper springs prior to actual  
operation of the mower.  
47  
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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 approximately  
1-1/ 2 to 2” of free play.  
If adjustment is required, turn the lock nut, illustrated  
below, to achieve a recommended 1-1/ 2 to 2” of free  
play.  
NOTE: Cable must have the recommended 1-1/ 2 to 2”  
of free play with parking brake released or drive  
belt may slip, causing loss of power.  
48  
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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  
death. All slopes require extra caution. If you cannot  
back up the slope or if you feel uneasy on it, do not  
mow it.  
WHEEL REVERSAL:  
*Installation instructions marked with an * asterisk are  
particularly important.  
1.  
Raise rear of mower and place suitable supports  
at the rear of the chassis.  
2.  
3.  
4.  
Remove rear wheel lug nuts and rear wheels.  
Reinstall rear wheels with valve stems inward.  
Install lug nuts.  
5. *Tighten lug nuts to a minimum torque factor  
of 50 ft. lbs.  
49  
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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.  
3.  
Swing out the control levers, start the engine, and  
release the paking brake.  
Raise the upper body to access hydro control linkage.  
If right wheel creeps, adjust right side linkage and  
vice-versa. Use procedure below.  
a. loosen, but do not remove, the bolt in  
the control tube (5540)  
b. loosen jam nuts on ends of the control  
rod (9067)  
c. turn control rod in or out until neutral  
is achieved  
d. tighten jam nuts on control rod  
e. tighten bolt in control tube  
9067 CONTROL ROD  
ADJUST IN STEP C  
5540 CONTROL  
TUBE  
JAM NUTS  
LOOSEN IN  
STEP B TIGHTEN IN STEP  
D
CONTROL TUBE BOLT  
LOOSEN IN STEP A  
TIGHTEN IN STEP E  
50  
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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 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.  
51  
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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 replaced.  
A. AIR GAP ADJUSTMENT  
1. It is not necessary to remove the clutch from the motor.  
2. Locate the three holes in the brake plate, one near each  
adjustment nut. (Figure 1)  
3. Insert a .012” feeler gauge into one of the three windows.  
Be careful to position the feeler gauge between the rotor  
and armature faces. (Figure 2)  
4. Tighten the adjustment nut adjacent to the window with  
the feeler gauge inserted until the gauge fits snugly  
between the rotor and armature. The gap should not be  
so tight that the feeler gauge cannot be reinserted after  
removal.  
5. Repeat steps 5 and 6 at the other two windows.  
6. Re-check the air gap at each window and make minor  
adjustments as necessary to achieve a consistent .012”  
air gap.  
Figure 1  
52  
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CARE AND MAINTENANCE  
PROCEDURE FOR ELECTRIC CLUTCH ADJUSTMENT  
(CONTINUED):  
B. OHMS TEST  
1.  
2.  
Disconnect clutch from mower wiring harness.  
Attach the two leads on multi-meter to the two  
wires coming from the electric clutch.  
3.  
4.  
5.  
The reading you receive should be between 2.5  
to 4.0 OHMS.  
If the resistance is outside this range, the clutch  
coil is faulty.  
If the clutch coil is faulty, the clutch must be  
replaced.  
Figure 2  
53  
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CARE AND MAINTENANCE  
FORWARD TRAVEL SPEED ADJUSTMENT:  
1.  
2.  
Drive machine on a smooth surface with both  
levers in top speed position.  
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 side and tighten nut.  
54  
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STANDARD SERVICE PARTS LIST  
50” Deck  
Blades:  
Belts:  
Hi-Lift - P/ N 9444 (Standard)  
Lo-Lift - P/ N 9443  
Engine to Mower Deck - P/ N 6111  
Serpentine - P/ N 1300  
Engine to T-Box - P/ N 7253  
T-Box to Hydros - P/ N 1765  
Grass Blower Belt - P/ N 4983  
60” Deck  
Blades:  
Belts:  
P/ N 9445 (Hi-Lift)  
Engine to Mower Deck - P/ N 6938  
Serpentine Belt - P/ N 6939  
Engine to T-Box - P/ N 7253  
T-Box to Hydros - P/ N 1765  
BRIGGS & STRATTON 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.  
Kohler (5023) Air Filter & Pre-Cleaner Kit - P/ N 78002  
Engine Oil Filter - P/ N 78006  
B&S (5020)  
Air Filter & Pre-Cleaner Kit - P/ N 79003  
Engine Oil Filter - P/ N 79006  
55  
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TROUBLESHOOTING  
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- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - charge or replace  
Solenoid- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Ignition switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Starter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Parking brake not on- - - - - - - - - - - - - - - - - - - - -engage parking brake  
2.  
3.  
ENGINE WILL TURN OVER BUT WON’T START  
No fuel- - - - - - - - - - - - - - - refuel and/ or clean or replace fuel filters  
HARD TO START ENGINE  
Fuel line clogged- - - - - - - - - - - - - clean fuel line and check fuel filter  
Faulty fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
4.  
ENGINE STARTS BUT CUTS OUT  
Water in fuel- - - - - - - - - - - - - - - -drain old fuel-replace with new fuel  
Clogged fuel line- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -check fuel filter  
Fuel tank vent plugged- - - - - - - - - - - - - - - - - - - - - - - - - - - -clean fuel vent  
Faulty fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - check vent  
5.  
ENGINE OVERHEATED  
Air intake screen or fins clogged- - - - - -clean intake screen and fins  
Oil level too low or too high- - - - - - - - - - - - - - - - - - - - - - - - - adjust oil level  
Running engine too slow - - - - - - - - - - - - - - - - - - - - - - - -run engine faster  
56  
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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 plugged- - - - - - - - - - - - - - - - - - - - - - - - - - -replace filter  
Bad transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Gear mating transmission/ gearbox disconnected- - - consult dealer  
7.  
MOWER LOSES POWER OR TRANSMISSION OVERHEATS  
Hydrostat belt loose. . . . . . . . . . . . . . . . . . . . . . . . adjust (see page 48)  
Hydrostat transmission oil too low or high- - - - - - -add or drain oil  
Transmission damage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Transmission blowing oil out cap- -overfilled or water contaminated  
8.  
ENGINE STALLS WHEN BLADES ARE ENGAGED  
Operator not on seat- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - sit on seat  
Faulty interlock system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Bad Blade spindle bearing- - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Deck drive belt not properly routed- - - - - - - - - - - - - - - - - - - - - - - -reroute  
Blades blocked by foreign material- - - - - - - - - - - - - - clean under deck  
9.  
DRIVE SYSTEM  
Low on power- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -check belt tension  
Mower pulls to side- - - - -check tire inflation/ adjust control linkage  
Mower creeps in neutral- - - - - - - - - - - - - - - - - - - -adjust control linkage  
10.  
CUT QUALITY  
Skips in spots- - - - - - - - - - - - check for loose belt/ slow ground speed  
Cut uneven left to right- - - - - - - - - -check tire inflation/ level the deck  
Poor dispersal of grass- - - - - - - - - - -clean deck/ check for loose belt  
Ends of grass blades are ragged- - - - - - - - - - - - - - - - - -sharpen blades  
57  
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NOTES  
58  
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OWNER  
INFORMATION  
DIXON INDUSTRIES, INC.  
a BLOUNT International Inc. Co.  
P.O. Box 1569  
Coffeyville, Ks 67337-0945  
620-251-2000  
FAX 620-251-4117  
Date Purchased _________________________________  
Mower Model Number ____________________________  
Mower Serial Number ____________________________  
Purchased From ________________________________  
Name  
________________________________  
Address  
________________________________  
DATE OIL CHANGED:  
DATE ENGINE TUNED:  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
59  
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ZTR®Mowers  
The engine exhaust from this product contains chemicals known  
to the State of California to cause cancer, birth defects or other  
reproductive harm.  
WARNING:  
Dixon® and ZTare 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  
5020 & 5023  
Part No. 13089-0601  
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