ZTR®
OPERATOR’S MANUAL
SERIES 5000
2003
IMPORTANT - READ CAREFULLY
The Dixon® ZTR® Mower is both easy and fun to operate. However, any power mower must be operated properly to be safe. It is not a toy or a recreational vehicle. Before you start to use the mower, read the operator’s manual carefully and become completely familiar with the controls.
The information contained in this manual applies to all Dixon® ZTR® 5000 Series Mowers. Your Dixon dealer will gladly answer any questions.
See your dealer for warranty service, parts and repairs.
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
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 55-56
Standard Service Parts List. . . . . . . . . . . . . . . . . . . .57-58
5000 Series
Part No. 13634-0702
3
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
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.
6
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 manufacturer’s 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
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.
8
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.
9
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.
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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
DIXON LIMITED WARRANTY POLICY - HYDRO GEAR MODELS
5000 - 6000 - 7000 Series Mowers
WARRANTY: Dixon Commercial Warranty is for a period of one (1) year from date of purchase or 400 hours of use, whichever occurs first. Mowers used for Homeowner Application (used only at owner’s primary place of residence) are warranted for two (2) years from date of purchase.
DIXON ZTR MOWERS ARE WARRANTED AGAINST DEFECTS IN MATERIALS AND 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 and 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 Dealer's place of business.
(b)Routine maintenance or adjustments
(c)Belts/Blades/Hydro 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 merchant ability 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.
Copies: Pink/Customer Yellow/Dealer White/Return to 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 and send copy to Dixon Industries, Inc.
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(Owner's Signature) |
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DIXON INDUSTRIES, INC.
A BLOUNT International Inc. Co. PO BOX 1569
COFFEYVILLE KS 67337 0945 PHONE 620 251 2000
FAX 620 251 4117
www.dixon-ztr.com
1-877-CUT-MORE
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SPECIFICATIONS |
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Model ZTR 5004/5005 |
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CHASSIS: |
11 GA - rectangular tube |
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BODY: |
Two piece-made of rotational molded polyethylene. Front |
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body contains access panels for battery service & engine |
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to mower deck belt removal. Rear body tilts up to allow |
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service on the entire drive system. |
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SEAT: |
Designed for operator comfort by use of high-density |
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closed cell foam padded back rest and arm rests, |
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upholstered with CorduraTM water-repellent fabric. Seat |
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is adjustable fore and aft. |
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MOWER DECK: |
Two decks are available. The 42” is made of stamped |
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steel. The 50” is made of 11 GA fabricated welded |
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construction with external reinforcement ribs. Three |
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blades combine for either a 42” or 50” cut width. Cut |
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height approximately 1.5” to 4.5” via 7 position lift handle. |
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BLADE DRIVE: |
Electric clutch |
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DRIVE SYSTEM: |
Each rear wheel is independently driven by a HydroGear |
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BDU-10L Series 70 hydrostatic transmission. The hydrostatic |
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transmissions power a fully enclosed HydroGear gearbox. |
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ENGINE: |
19HP Kawasaki overhead valves, replaceable oil filter, full |
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pressure lube system, dual element air cleaner, integral fuel |
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pump. |
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STARTING SYSTEM: Electric by key switch operation with safety interlocks on |
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parking brake and blade drive clutch. |
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TIRES: |
Front |
11 X 4 X 5 ribbed tread |
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Rear |
20 X 10 X 8 Multi-Trac |
RECOMMENDED |
Front |
16 - 21 lbs. |
TIRE PRESSURE: |
Rear |
8 - 14 lbs. |
CAPACITIES: |
Fuel - 4.8 gallons total (dual tanks) |
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Oil tank - 3 quart with in-line 40 micron filter |
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Engine - 2 qts. SAE 30 (with filter) |
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DIMENSIONS: |
Width |
55” (42” Deck), 60” (50” Deck) |
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Height |
45” |
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Length |
72: |
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Weight |
594 lbs, (42” Deck], 650 lbs (50” Deck) |
Additional information provided in service instructions under the individual component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
13
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SPECIFICATIONS |
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Model ZTR 5023 |
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CHASSIS: |
11 GA - rectangular tube |
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BODY: |
Two piece - made of high-density polyethylene. Front body contains |
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access panels for battery service and engine to mower deck belt |
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removal. Rear body tilts up to allow service on the entire drive |
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system. |
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SEAT: |
Designed for operator comfort by use of high density closed cell |
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foam padded back and arm rests, upholstered with CorduraTM |
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water-repellent fabric. Seat is adjustable fore and aft. |
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MOWER DECK: |
Two decks are available. The 60" is made of stamped steel. The |
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50" is made of 11 GA fabricated welded construction with external |
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reinforcement ribs. Three blades combine for a 50" or 60" cut |
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width. Cut height approximately 1.5" to 4.5" via 7 position lift |
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handle. |
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BLADE DRIVE: |
Electric clutch |
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DRIVE SYSTEM: |
Each rear wheel is independently driven by a HydroGear BDU-10L |
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Series 70 hydrostatic transmission.The hydrostatic |
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transmissions, in turn, power a fully enclosed HydroGear gearbox. |
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ENGINE: |
23HP Kohler Command, 4-Cycle, V-Configuration, Overhead Valve, |
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Air-Cooled, Gasoline, Vertical Shaft, Aluminum Head, and Crankcase |
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with Cast Iron Liners, Full Pressure Lubrication/Full Flow Filter, |
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Pulse-type Fuel Pump, Fixed Jet Carburetor w/Smart-Choke, |
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Electronic Ignition, In-Line Fuel Filter, Dual Element Air Cleaner. |
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STARTING SYSTEM: |
Electric by key switch operation with safety interlocks on parking |
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brake and blade drive clutch. |
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TIRES: |
Front |
11 X 4 X 5 Ribbed Tread |
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Rear |
20 X 10 X 8 Multi Trac |
RECOMMENDED |
Front |
16 - 21 lbs. |
TIRE PRESSURE: |
Rear |
8 - 14 lbs. |
CAPACITIES: |
Fuel - 4.8 gallons total (dual tanks) |
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Hydrostat oil tank - 3 quart with in-line 40 micron filter |
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Engine - 2 qts. SAE 10W30 (with filter) |
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DIMENSIONS: |
Width |
60"(50" Deck), 72"(60" Deck) |
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Height |
45" |
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Length |
72" |
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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.Slide seat forward or backward.
3.Release seat slide adjuster.
15
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 mower’s 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.
16
CONTROLS
CHOKE CONTROL LEVER:
•Located on control panel to operator’s right.
•Used to start a cold engine.
THROTTLE CONTROL LEVER:
•Located on control panel to operator’s right.
•Controls engine speed, slow to maximum.
•While moving, throttle control should be set to MAXIMUM for wide open setting to insure adequate cooling of the engine and to maintain mower deck blade speed.
17
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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