Operator's Manual
5000 SERIES
ZTR® MOWERS
2001
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INDEX
SAFETY ..................................................................Pages 4- 9
WARRANTY POLICY............................................Page
SPECIFICATIONS .................................................Page 11-13
SEAT ADJUSTMENT ............................................Page 14
10
CONTROLS ...........................................................Pages 15-18
OPERATION INSTRUCTIONS ...........................Pages 19-25
CAREAND MAINTENANCE ...............................Pages 26-41
STANDARD SERVICE PARTS LIST .....................Page 42-43
TROUBLESHOOTING .........................................Pages 44-46
5000 Series
Part No. 13093-0600
a
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SAFETY
RIDING LAWNMOWERS, IF IMPROPERLY OPERATED,
CAN CAUSE SERIOUS INJURY OR DEATH
The most common causes of injury to the operator or bystander...
BLADE CONTACT
TIP-OVER
BACK-OVER
RUN-OVER
...read and understand this manual to prevent injuries.
Page 4
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SAFETY
SAFETY SYMBOLS
Safety Alert Symbol
When you see this symbol,
BE ALERT to the potential for injury.
Follow recommended safety precautions and safe operating
practices.
Danger
indicates an imminently hazardous situation which, if
not avoided, will result in death or serious injury.
Warning
indicates a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
Caution
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.
Page 5
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SAFETY
Thiscuttingmower iscapableofamputatinghands&feet,
andthrowingobjects.
Failuretoobservethefollowingsafetyinstructionscouldresultin
seriousinjuryor 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.
Nevercarrypassengers.
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.
•
•
•
•
•
•
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 loading or unloading the mower into a trailer or truck. Do not ride the mower when
loading & 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 manufacturer's recommendation for wheel weights or counterweights.
Maintain or replace safety & instruction labels, as necessary.
•
The engine exhaust from this product contains chemicals known to the
StateofCaliforniatocausecancer, birthdefectsor other reproductiveharm.
WARNING:
Page 6
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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.
Useextracarewith grasscatchersor other attachments. Thesecan changethestabilityofthemower.
Keepallmovement ontheslopesslowandgradual. Donot makesuddenchangesinspeedordirection.
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.
Donot mowneardrop-offs,ditches,orembankments. Themowercouldsuddenlyturn overifawheel
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.
Page 7
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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.
12 VOLT UTILITY OUTLET
A utility outlet is provided for use with 12 volt DC attachments. It is located just ahead of the
instrument panel.
Output is limited to 5 amps.
We do not recommend the use of sound equipment (such as CD players with earphones) that
could interfere with the operators hearing. The operator may not hear impending hazards and
could be distracted from the safe operation of the mower.
Page 8
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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 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 where there is an open flame,
If fuel is spilled on clothing, change clothing immediatley.
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 gas-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 gasoline dispenser nozzle.
If a gasoline 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.
•
•
•
•
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.
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
servicingthem.
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.
Page 9
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DIXON INDUSTRIES, INC.
a BLOUNT company
AIRPORT INDUSTRIALPARK
PO BOX 1569
COFFEYVILLE KS 67337 0945
316 251 2000
FAX 316 251 4117
DIXON LIMITED WARRANTY POLICY - COMMERCIAL MODELS
Models 6000 & 7000
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 1 year from
the date of purchase. Commercial use is specified as use other than, or in addition to, mowing at owner's 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.
2.
Warranty applies only to original retail purchaser of new and unused mowers and accessories.
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.
4.
5
Battery warranty: Limited to 90 days from date of purchase.
Accessories Warranty (Grass Catchers, Snow Blades, Covers, etc.): Limited to 90 days from date of purchase.
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 dealer's
place of business.
(b) Routine maintenance or adjustments.
(c) Belts/cutting blades/HydroGear filters.
(d) Engines -- All engines used on Dixon ZTR mowers are warranted by each individual engine
manufacturer.
(e) Any costs or expense of providing substitute equipment while repair work is being performed on a
warranted mower.
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 customer's signature &send copy to Dixon Industries, Inc.
DATE OF PURCHASE
MODEL
S/N
Owner's Name
Address
Dealership
Address
Owner's Signature
Dealer's Signature
Page 10
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SPECIFICATIONS
Model ZTR 5020
CHASSIS:
BODY:
11 GA - rectangular tube
Twopiece-madeofrotationalmoldedpolyethylene. Front bodycontainsaccesspanelsfor
batteryserviceandenginetomowerdeckbelt removal. Rearbodytiltsuptoallowserviceon
the entire drive system.
SEAT:
Designedforoperatorcomfort byuseofhigh densityclosedcellfoampaddedbackrest and
armrests,upholsteredwithCorduraTM water-repellentfabric. Seatisadjustableforeandaft.
MOWERDECK:
2Decksareavailable. 60"ismadeofstampedsteel. 50"ismadeof 11GA fabricatedwelded
construction withexternalreinforcement ribs. 3bladescombineforeithera50" or60" cut
width. Cut height approximately 1.5" to 4.5" via 7 position lift handle.
BLADEDRIVE:
DRIVESYSTEM:
Electricclutch
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:
20HP Briggs & Stratton Intek, overhead valves, replaceable oil filter, full pressure lube
system, dualelement air cleaner, integralfuelpump.
STARTING SYSTEM:
TIRES:
Electric by key switch operation with safety interlocks on parking brake and blade drive
clutch.
Front
Rear
11 X 4 X 5 Ribbed Tread
20 X 10 X 8 Multi Trac
RECOMMENDED
TIREPRESSURE:
Front
Rear
16 - 21 lbs.
8 - 14 lbs.
CAPACITIES:
DIMENSIONS:
NOTE:
Fuel-4.8gallonstotal(dualtanks)
Hydrostat oil tank - 3 quart with in-line 40 micron filter
Hydrostat oilrecommendation, refer topage39
Engine - 2 qts. SAE 30 (with filter)
Width
Height
Length
Weight
60"(50"Deck),73"(60"Deck)
45"
72"
668 lbs. (50" Deck), 685 lbs. (60" Deck)
Additionalinformation provided in serviceinstructionsunder theindividualcomponent.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
Page 11
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SPECIFICATIONS
Model ZTR 5023
CHASSIS:
BODY:
11 GA - rectangular tube
Two piece - made of high-density polyethylene. Front body contains access panels for
batteryserviceandenginetomowerdeckbelt removal. Rearbodytiltsuptoallowserviceon
the entire drive system.
SEAT:
Designedforoperatorcomfort byuseofhighdensityclosedcellfoampaddedbackandarm
rests, upholstered with CorduraTM water-repellent fabric. Seat isadjustableforeand aft.
MOWERDECK:
2Decksareavailable. 60"ismadeofstampedsteel. 50"ismadeof11GAfabricatedwelded
construction withexternalreinforcement ribs. 3bladescombineforeithera50" or60" cut
width. Cut height approximately 1.5" to 4.5" via 7 position lift handle.
BLADEDRIVE:
DRIVESYSTEM:
Electricclutch
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:
23HPKohlerCommand,4-Cycle,V-Configuration,OverheadValve,Air-Cooled,Gasoline,
Vertical Shaft, Aluminum Head, and Crankcase with Cast Iron Liners, Full Pressure
Lubrication/FullFlowFilter,Pulse-typeFuelPump,FixedJet Carburetorw/Smart-Choke,
ElectronicIgnition,In-LineFuelFilter,DualElement AirCleaner.
STARTING SYSTEM:
TIRES:
Electric by key switch operation with safety interlocks on parking brake and blade drive
clutch.
Front
Rear
11 X 4 X 5 Ribbed Tread
20 X 10 X 8 Multi Trac
RECOMMENDED
TIREPRESSURE:
Front
Rear
16 - 21 lbs.
8 - 14 lbs.
CAPACITIES:
DIMENSIONS:
NOTE:
Fuel-4.8gallonstotal(dualtanks)
Hydrostat oil tank - 3 quart with in-line 40 micron filter
Hydrostat oilrecommendation, refer topage39
Engine - 2 qts. SAE 10W30 (with filter)
Width
Height
Length
Weight
60"(50"Deck),72"(60"Deck)
45"
72"
680lbs.(50" Deck), 685lbs.(60" Deck)
Additional information provided in service instructions under the individual component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
Page 12
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SPECIFICATIONS
Model ZTR 5017Twin
CHASSIS:
BODY:
11 GA - rectangular tube
Twopiece-madeofrotationalmoldedpolyethylene. Front bodycontainsaccesspanelsfor
batteryserviceandenginetomowerdeckbelt removal. Rearbodytiltsuptoallowserviceon
the entire drive system.
SEAT:
Designedforoperatorcomfort byuseofhigh densityclosedcellfoampaddedbackrest and
armrests,upholsteredwithCorduraTM water-repellentfabric. Seatisadjustableforeandaft.
MOWERDECK:
2 Decksareavailable. 42" isconstructed of13 gastamped steel. 50" isafabricated deck. 3
bladescombineforeithera42"or50"cut width. cut width. Cut height approximately1.5"
to 4.5" via 7 position lift handle.
BLADEDRIVE:
DRIVESYSTEM:
Electricclutch
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:
17HP Briggs & Stratton V-Twin, overhead valves, replaceable oil filter, full pressure lube
system, dualelement air cleaner, integralfuelpump.
STARTING SYSTEM:
TIRES:
Electric by key switch operation with safety interlocks on parking brake and blade drive
clutch.
Front
Rear
11 X 4 X 5 Ribbed Tread
18 X 9.5 X 8 Multi Trac
RECOMMENDED
TIREPRESSURE:
Front
Rear
16 - 21 lbs.
8 - 14 lbs.
CAPACITIES:
DIMENSIONS:
NOTE:
Fuel-4.8gallonstotal(dualtanks)
Hydrostat oil tank - 3 quart with in-line 40 micron filter
Hydrostat oilrecommendation, refer topage39
Engine - 2 qts. SAE 30 (with filter)
Width
Height
Length
Weight
54" (42" Deck), 60" (50" Deck)
45"
72"
615 lbs (42" Deck), 668 (50" Deck)
Additionalinformation provided in serviceinstructionsunder theindividualcomponent.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
Page 13
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SEAT ADJUSTMENT
INSTRUCTIONS
5000 Series
1. Grasp seat slide adjuster and move it into adjustment position.
2. Slide seat forward or backward.
3. Release seat slide adjuster.
Seat Slide Adjuster
Page 14
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CONTROLS
Page 15
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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.
.
Engage parking brake before starting engine
CAUTION
TO SET PARKING BRAKE:
The hand operated parking brake is located at left hand side
of 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 DRIVE 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.
Page 16
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CONTROLS
(left turn opposite)
TO GO FORWARD:
From neutral position, gently 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 the right lever.
To turn "square corners" move lever of desired direction to neutral.
To turn on mower's own axis (zero turning radius) stop and move one lever to reverse position and
the other to forward position.
BRAKING:
Tobrakemower,movebothleversindirectionoppositeoftravel,releaseleverstoneutral,set parking
brake. Park only on level surfaces.
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 mowing, throttle control should be set to the MAXIMUM or wide open setting to insure
adequate cooling of the engine and to maintain mower deck blade speed.
Page 17
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CONTROLS
BLADEDRIVE:
Located on control panel, on operator's right.
To engage blades: Pull up on the switch.
To disengage blades: Push down.
CIRCUIT BREAKER:
Located on control panel, on operator's 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.
Page 18
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OPERATION INSTRUCTIONS
Safe and successful operation 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 allowanyonetooperatethemowerwithout completeknowledgeofallcontrolsandtheirfunctions.
During initial operation, "learning to drive", set throttle at slow speed.
Sound judgement by the operator will prevent accidents.
DRINK/CUP HOLDER located on left rear fender is for transport or carrying ONLY!
Mower usage requires that both hands be free to control individual levers.
DO NOT ATTEMPT operation of mower with any type of
container or other object in either hand.
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 on this mower.
BEFORE OPERATING MOWER:
1. Read engine manufacturer's operating and maintenance instructions.
2. Discuss proper maintenance with your dealer.
3. Read and observe all safety instructions on your mower and in the manual.
4. Check engine oil.
5. Be sure gas cap is in place.
6. Be sure parking brake is on.
7. Be sure mower blade drive is off.
8. Know how to stop engine. (Turn key to off position)
Page 19
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OPERATION INSTRUCTIONS
TESTING OF SAFETY INTERLOCK SYSTEMS:
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!
Page 20
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OPERATION INSTRUCTIONS
STARTING INSTRUCTIONS: Cold Engine
1. Position choke control in ON position.
2. Position throttle control at 1/2 speed setting.
3. Insert ignition key and turn to "Start" position.
When engine starts, release ignition key. Key
will return to "Run" position.
4. Once engine starts to warm up, slowly move
choke control to OFF position.
5. Move throttle control to the FAST position.
6. 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.
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 ZTR 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.
CAUTION
DO NOT operate the engine in an enclosed area. The exhaust
fumes are toxic.
Page 21
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OPERATION INSTRUCTIONS
MOWING WITH A MULCHING ATTACHMENT:
Mulchingorrecyclingthegrassclippingsrequiresatotallydifferent mowingapproachthanwouldbenormal
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.
2.
Set the engine speed control to the wide open or full setting.
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.
4.
5.
6.
7.
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.
Do Not Attempt To Cut Grass When It Is Wet. Mulching performance will be very poor under
wet grass conditions.
Maintain Sharp Blades Throughout The Cutting Season. This is very important. Optimal
mulching performance cannot be obtained with dull or nicked blades.
Keep The Underside Of The Mower Deck Clean. Remove all grass and dirt buildup 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!
Page 22
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OPERATION INSTRUCTIONS
MOWING WITH A GRASS CATCHER ATTACHMENT:
In order toachieveoptimum performancewhen mowingwith agrasscatchingattachment, pleaseread and
follow the tips listed below:
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 both the underside of the deck and
the attachment chutes. Empty bags often to prevent plugging.
3.
4.
5.
Ifthegrassistall,placethemowerdeckcut height selectorin thetoporsecondnotch. Initiallyoverlap
cutting swaths instead of a full swath with each pass.
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 blades. Some grass catching attachments require a "high-lift" blade. See your
dealer for advice on the type of blades needed for your mower.
6.
7.
Maintain Sharp Blades Throughout The Cutting Season.
Operatethemowerat aslowergroundspeedthan when mowingwithout agrasscatchingattachment.
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.
Disengagebladeandstopenginepriortoclearinggrassfromeitherthedischargechuteorgrasscatcher
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 bags.
Page 23
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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.
Be sure that deflector is properly
installed on the discharge chute.
CAUTION
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 the underside of the deck and
dischargearea.
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. Keep The Underside Of The Mower Deck Clean. Frequent removal of dried grass and dirt will allow
the clippings to discharge correctly.
5. Maintain Sharp Blades Throughout The Cutting Season.
GRASS HEIGHT SUGGESTIONS:
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 buildup
in a healthy lawn. Some locations and applications may require slightly different cut heights. If in
doubt, consult your local lawn professional for assistance.
Do not cut any more than 1/3 of the grass blade length.
Grass Types:
Best Cut Heights:
Zoysia
2" - 2 1/2"
1 1/2" - 3"
1 1/2" - 3"
1 1/2" - 2"
3" - 4"
Blue Grass
Fescue Blends
St. Augustine (Mid South)
St. Augustine (Deep South)
Tifton Bermuda
Centipede
1 1/2"
1 1/2" - 2"
1 1/2" - 2"
2"
Common Bermuda
Bahia/Argentina/Pensacola
Page 24
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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.
Height:
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.
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.
Page 25
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CARE AND MAINTENANCE
This portion of the owner's manual deals with normal service items which can be performed by the owner. Please
rememberthat ifyouarein doubt astothecorrect serviceprocedurestobefollowed,theseandotherservicesituations
can be handled by a Dixon ZTR dealer who is familiar with the service of your mower.
MAINTENANCE SCHEDULE:
Toinsurealongandtroublefreeservicelifeofallcomponents,aregularandthoroughmaintenance
schedule should be followed. The following items should be checked after the first (10) hours of
operation and on a weekly basis, or each (40) hours of use:
(Items marked with an asterisk * require more frequent attention)
1.
2.
3.
4.
5.
6.
Drive system, belts and controls.
Mower deck belts.
Tirepressures.
Hydro oil tank.
Tightness of all nuts and bolts.
Battery fluid level.
7. * Engine oil. (Before each use or every 8 hours)
8. Electric blade clutch air gap setting.
Before performing any maintenance, shut off engine,
allow to cool.
CAUTION
ENGINE: For engine operating and maintenance information, refer to the engine operating and
maintenance instructions furnished by the engine manufacturer, supplied with each mower.
BATTERY: Check the fluid in the battery at frequent intervals.
Keep fluid level above the plates in each cell, using distilled water.
OFF-SEASON BATTERYSTORAGE:
Identify each cable so cables can be reconnected to correct terminals.
Disconnect cables from terminals.
ALWAYS disconnect ground cable first and reconnect last.
Chargebattery.
DO NOT remove battery from mower.
Clean top of battery and terminals with baking soda and water.
Page 26
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CARE AND MAINTENANCE
MOWER BLADE MAINTENANCE:
NOTE: Observe proper blade position prior to removal.
1. Safely raise front of mower.
2. Hold or block blade from turning.
3. Loosen blade nut and remove blade.
4. When replacing blade, tighten blade nut securely. Refer to diagram.
Wear heavy, thick gloves when holding onto mower blade, avoid the sharp
edge of the blade.
CAUTION
NOTE: Be sure blade is centered on pilot before tightening nut to 60 ft. lbs. torque.
Page 27
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CARE AND MAINTENANCE
BELT TENSION
ENGINE TO MOWER DECK BELT:
42" and 50"
60"
P/N 6111
P/N 6938
The engine to mower deck drive belts are automatically held in proper tension by springs
which push the deck assembly forward and do not require any additional adjustment to be
made.
MOWER DECK SERPENTINE BELT:
42"
50"
P/N 6109
P/N 1300
P/N 6939
60"
Refer to illustration for adjustment procedure.
NOTE: Belt deflection or movement should be approximately 1/4" when measured at
mid-point between pulleys.
Periodically inspect both belt and idler systems.
Page 28
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CARE AND MAINTENANCE
FUEL SHUT OFF VALVE:
A fuel shut off valve is located at the bottom rear of each fuel tank.
Always turn the valve to the "OFF" position when the mower is stored or not in use.
LUBRICATION
CHASSIS:
Number of grease zerks used: (5)
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
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 design.
Page 29
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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. Remove rear wheel lug nuts and rear wheels.
3. Reinstall rear wheels with valve stems inward.
4.* Install lug nuts with "flat" side of nut against wheel.
5.* Tighten lug nuts to a minimum torque factor of 50 ft. lbs.
Page 30
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CARE AND MAINTENANCE
CAUTION
HOT oil may cause burns. Allow engine to cool before draining oil.
CHANGING THE ENGINE OIL:
1. The "Dapco" oil drain valve is located on the left side of the engine crankcase.
2. Place a suitable container under the drain valve. The short piece of hose will help
direct the oil.
3. To drain turn hex head valve stem counter clockwise with 10mm wrench or socket.
Open to full (approximately 7 turns).
4. After engine is drained tighten hex stem..
NOTE: Refer toenginemanufacturersrecommendationsforfrequencyofoilchanges.
Hex Head
Valve Stem
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.
NOTE: Engineoilchangeson the5000SeriesModelswillrequirereplacement oftheoilfilter.
ThesefilterscannowbeobtainedfromanyauthorizedDixonDealer.
PROTECT YOUR INVESTMENT:
The use of non-original oil or air filters may result in damage to the engine and a loss of
warranty. Listed on Page 43 are the correct part numbers for each engine in the 5000
Series Dixon Mowers.
PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS
PROTECT YOUR ENVIRONMENT
Page 31
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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
LINKHERE
5283
LINK
FRONT OF
LIFT
FRAME
2. Remove front and rear deck hanger pins, as illustrated below.
3. Slide deck from beneath chassis.
4. Reverse procedure to reinstall deck to chassis.
Page 32
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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 lock nuts on the bottom which can be turned up or down to raise or lower the front and rear of the mower deck.
Deck should be level or pitched slightly higher in rear.
A. Placethemoweron asmoothlevelsurface,checktirepressurestoinsurethemowerhasacorrect
stance. Inflate tires as required:
Front: 16 - 21 lbs maximum
Rear : 8 -14 lbs maximum
B. Turn each outer blade tip to align with the deck or in a side to side manner.
C. Measurefromthefloorsurfaceuptothebottomofthebladetiponthedischargesideofthemower
deck. Retain thismeasurement. Movetotheoppositeside,checkthat measurement isthesame.
Ifadjustment isrequired, turn thenut on thebottom ofthefront threaded adjuster up or down
until both side to side measurements are equal. Retain measurement.
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 1/8th of an inch 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 lock nut up.
E. Confirm measurements once again. Blade tips should be level in a side to side manner. In the
rear, bladetipsshouldbelevelto1/8" higher than sidetosidemeasurement. In thefront, blade
tips should be level to 1/8" lower than side to side measurement.
NOTE:
Thiswillplacethemowerdeckin abasemeasurement position. Additionaladjustment
mayberequiredtoachievedesiredcut forthetypeofgrassorconditionsbeingmowed.
Front
Adjusters
Left Rear Adjuster
Deck Leveling Adjustment Points
Page 33
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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
an inch free play or movement 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 springs must be positioned to depress
the bypass relief pins. Remove bypass keeper springs prior to actual operation of the
mower.
Page 34
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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 34.
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 inches of free play.
If adjustment is required, turn the lock nut illustrated below to achieve a recommended 1-1/2 to 2
inches of free play.
NOTE:
Cable must have the recommended 1-1/2 to 2 inches of free play with parking brake
released or drive belt may slip, causing loss of power.
Page 35
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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. 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 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)
9067CONTROLROD
ADJUST IN STEPC
c. turn control rod in or out until neutral is achieved
5540CONTROL
TUBE
d. tighten jam nuts on control rod
JAM NUTS LOOSEN
IN STEP B TIGHTEN IN
e. tighten bolt in control tube
STEP D
4. Engage parking brake and lower the body.
Release parking brake and swing control levers in. If wheel
creeps, repeat step 3.
CONTROLTUBEBOLT
LOOSEN IN STEPA
TIGHTEN IN STEP E
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.
Page 36
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CARE AND MAINTENANCE
FORWARD TRAVEL SPEED ADJUSTMENT:
1. Drive machine on a smooth, level 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
leversarenowuneven at top speed, loosen controllevermountingnut. Rotatelevertobeeven with other
side and tighten nut.
Page 37
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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 inch 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 adjusting 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
Figure 1
feeler gauge cannot be reinserted after removal.
5. Repeat Steps 5 and 6 at the other two windows.
6. Recheck the air gap at each window and make minor adjustments
as necessary to achieve a consistent .012 inch air gap.
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
2.4 to 2.9 OHMS.
4. If the resistance is outside this range the
clutch coil is faulty.
Figure 2
5. If the clutch coil is faulty, the clutch must be
replaced.
Page 38
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CARE AND MAINTENANCE
HYDROSTATIC TRANSMISSION OIL AND FILTER SERVICE
SERVICE INTERVALS:
OIL REQUIREMENTS:
1. Initial filter service - 50 hours.
2. Every 250 hours or once a year thereafter.
Any high quality engine oil with an API classification of SG/CD
is recommended.
RECOMMENDED OIL WEIGHT: Normal operation temperatures - 20 W 50
Cold climate usage - 10 W 40
Another alternative that will provide excellent all climate
performance and extended time between oil changes is
a 15 W 50 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.
Page 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.
Proceed as follows:
1. Remove oil filter from chassis, allowing oil to drain into container. Clean impurities from inside
of reservoir, if necessary.
2. Install new oil filter to chassis. Use only genuine Dixon replacement oil filter.
3. Put fresh oil in reservoir. Fill reservoir to the full mark.
4. Remove two oil return hoses from top of oil reservoir and direct these hoses into a container for
oil draining.
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 and contains no bubbles, stop the engine.
9. Reattach oil return hoses to top of reservoir.
10. Release by-pass valve on both hydros.
11. Add sufficient oil to reservoir to return oil level to the full mark.
Page 40
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CARE AND MAINTENANCE
WHEELS AND TIRES:
Correct tirepressureisimportant forcorrect operationofmower.
Front Tires
RearTires(5020&5023)
Rear Tire (5425)
11 x 4 x 5
20 x 10.5 x 8 8-14 lbs.
18 x 9.5 x 8 8-14 lbs.
16-21 lbs.
NOTE: Check lug nuts periodically for tightness.
Keep all connections clean and tight.
ELECTRICAL SYSTEMS:
CLEANING THE MOWER: Wash mower periodically.
Clean above and below deck.
NOTE: Allow mower to cool before washing. If bearings are
hot,theywilldrawmoistureinsideastheydryandcause
corrosion.
SERIALNUMBERS:
The serial number is located on frame at rear of engine.
WARRANTY:
Refer to Warranty Registration Form.
PARTS/SERVICE:
See your Dixon dealer for replacement parts, warranty or service.
PLEASE HELP PROTECT THE ENVIRONMENT BY AVOIDING ALL
CHEMICALS WHICH MAY DAMAGE OR CAUSE HARM TO PLANTS AND
ANIMALS IN YOUR AREA
Page 41
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STANDARD SERVICE PARTS LIST
42" DECK
BLADES: Lo Lift
Standard Hi-Lift
P/N 6236
P/N 8688
BELTS:
Engine to Mower Deck P/N 6111
SerpentineBelt
Engine to T-Box
T-Box to Hydros
Grass Blower Belt
P/N 6109
P/N 7253
P/N 1765
P/N 4983
50" DECK
BLADES: Lo-Lift
Standard Hi-Lift
P/N 9443
P/N 9444
BELTS:
Engine to Mower Deck P/N 6111
SerpentineBelt
Engine to T-Box
T-Box to Hydros
Grass Blower Belt
P/N 1300
P/N 7253
P/N 1765
P/N 4983
60 " DECK
BLADES: Hi-Lift
P/N 9445
BELTS:
Engine to Mower Deck P/N 6938
SerpentineBelt
Engine to T-Box
T-Box to Hydros
P/N 6939
P/N 7253
P/N 1765
Page 42
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STANDARD SERVICE PARTS LIST
KOHLER AND BRIGGS & STRATTON AIR AND OIL FILTER PART NUMBERS:
Refer to engine manufacturers manual for recommendations regarding frequency of service required
for engine oil changes and air filter maintenance.
Protect your engine investment, use only original equipment filters.
Kohler
5023
Air Filter & Pre-Cleaner Kit
Engine Oil Filter
78002
78006
Briggs & Stratton
5020/5425
Air Filter & Pre-Cleaner Kit
Engine Oil Filter
79003
79006
Page 43
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TROUBLESHOOTING
MOWER CUT QUALITY:
There are many variables that can affect the cut quality of any riding mower. Type and conditions of grass,
cut height setting, engine RPM and ground speed are some of the variables that interact creating differences
in cut quality. Examination of one or more of the above will generally produce a quality cut.
TheTroubleshootingChart suggestspracticesandadjustmentsthat maybehelpfulin improvingcut quality.
Your Dixon ZTR dealer is also available to provide assistance to you.
SITUATION
Poor cut quality
Poor cut quality
CAUSES
REMEDY
Ground speed
Reduce mowing speed.
Refer to page 42 for part numbers.
Incorrect engine to
mower deck belt
Poor cut quality
Poor cut quality
Poor cut quality
Engine RPM too low
Dull or bent blade
Increase engine RPM to maximum.
Sharpen or replace as required.
Un-level mower deck
Refer to page 33 for deck leveling
procedure.
Poor cut quality
Poor cut quality
Poor cut quality
Grass buildup under
mower deck
Clean out underside of mower deck.
Refer to page 42 for part numbers.
Improper blades
Uneven tire pressures
Refer to page 41 for correct tire
pressures.
Page 44
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TROUBLESHOOTING
DRIVE SYSTEM:
SITUATION
CAUSES
REMEDY
Mower pulls to one
side or the other
Forward travel
speedadjustment
Refer to page 37 for procedure
or consult your dealer for repair.
Drive system will not
Incorrect oil filter installed Replace with correct Dixon
function on either side after on system.
changinghydrostatic
filter.
transmission oil and filter
Hydrostatictransmissions
Consult your dealer for repairs.
are "air locked", low or no Continued attempted operation may
oil return to tank.
result in damage to the system.
Drive system functions on
one side only
Loss of set screw tension on Consult your dealer for repairs.
hydrostatictransmission
pulley.
Loss of power and speed on Incorrect parking brake
Refer to adjustment procedure page 35
or consult your dealer for repair.
bothhydrostatic
transmissions
cableadjustment
Incorrect or worn drive
belt
Replace with correct belt.
NeutralAdjustment
Mower creeps in
neutral position
Refer to adjustment procedure page 36 or
consult your dealer for repair.
Page 45
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TROUBLESHOOTING
ELECTRICAL SYSTEM:
SITUATION
CAUSES
REMEDY
Starter will not
turn engine over
Circuit breaker
disengaged
Push button to reset
Consult your dealer for repair
Starter will not
Dead battery
Chargebattery
turn engine over
Batterydischarge
Poor connections on
battery
Tighten or replace as required
Battery water low
Wrong battery installed
in mower
Batterydischarge
Batterydischarge
Engine electrical system
not functioning correctly
Have electrical system checked by
your dealer
Engine being operated
at too low an RPM
Increase engine RPM
Contact your dealer for information
NOTE: Electricalsystem failuresaregenerallysimplein nature, alwayschecktheobviousfirst and then
moveontothemorecomplicatedpartsused. Poorbatteryservice,looseconnections,corrosion,
frayed or broken wiring, are more likely than component failure.
Page 46
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DIXONINDUSTRIES,INC.
ABLOUNTInternationalInc.Co.
PO BOX 1569
COFFEYVILLEKS 673370945
316 251 2000
FAX 316 251 4117
OWNER
INFORMATION
DATE PURCHASED
MOWER MODEL NUMBER
PURCHASED FROM
Name
Address
MOWER SERIAL NUMBER
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.
WARNING:
Dixon® and ZTR® are registered trademarks of Dixon Industries, Inc.
DIXON INDUSTRIES, INC.
A BLOUNT INTERNATIONAL INC. CO.
PO BOX 1569
COFFEYVILLE KS 67337 0945
316 251 2000
5000Series
5020,5023&5425
Part No. 13089-0600
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