Dixon ZTR 5423 User Manual
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 in this operator's, manual applies to all Dixon® ZTR® 5000 Series Model
Mowers. Your Dixon dealer will gladly provide a check-out ride and answer any questions.
See your dealer for warranty service, parts and repairs.
Dixon Industries, Inc.
A BLOUNT International, Inc. Company
P.O.Box 1569
Coffeyville, KS 67337-0945
316-251-2000
INDEX
SAFETY...............................................................Pages 1 - 6
WARRANTY POLICY ..........................................Page 7
SPECIFICATIONS ...............................................Page 8- 10
SEAT ADJUSTMENT...........................................Page 11
CONTROLS.........................................................Pages 12-15
OPERATION INSTRUCTIONS.............................Pages 16-23
CARE AND MAINTENANCE ................................Pages 24-38
STANDARD SERVICE PARTS LIST .....................Page 39 - 40
TROUBLESHOOTING .........................................Pages 41 - 43
DIAGRAMS..........................................................Pages 44-62
Part No. 8965
September 1996
BLADE CONTACT
RIDING LAWNMOWERS, IF IMPROPERLY OPERATED,
CAN CAUSE SERIOUS INJURY OR DEATH
The most common causes of injury to the operator or bystander...
TIP-OVER
RUN-OVER
RUN-OVER
Page 1
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 2
This cutting mower is capable of amputating hands and feet, and throwing objects.
Failure to observe the following safety instructions could result in
serious injury or death.
GENERAL OPERATION:
• Read, understand, and follow all instructions in the manual and on the mower before starting.
• Only allow responsible adults, who are familiar with 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.
• 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.
The Engine Exhaust from this product contains chemicals known to the
State of California to cause cancer, birth defects or other reproductive harm.
Page 3
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.
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.
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.
Page 4
CHILDREN:
Page 5
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.
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.
• Never run a mower inside a closed area.
• Keep nuts and bolts, especially blade attachment bolts, tight 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 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.
• Check to assure that the drive chains are properly adjusted. A loose chain may come off
causing loss of control. This statement applies to chain drive models 2301, 3000 & 4000
Series.
'; :,'
Page 6
DIXON LIMITED WARRANTY POLICY-- HYDRO-GEAR MODELS
This warranty policy applies to all HydroGear mowers or any 50" model, purchased on or after March 1,1990.
WARRANTY: Dixon Warranty term is for a period of one (1) year from date of purchase or 400 hours of use, whichever
occurs first. Mowers used for residential homeowner applications (used only at owner's primary place of residence) are
warranted for two (2) years from date of purchase or 400 hours of use, whichever occurs first. 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, Tine Rakes, 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 noLcovered 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 / chains / sprockets / cutting blades.
(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.
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.
DATE OF PURCHASE
(Owner's Name)
(Address)
_______________________
Model
________________
(Dealership)
(Address)
(Dealer's Signature)
S/N DM'
____________
(Owner's Signature)
SEE DEALER FOR DETAILS
Page 7
SPECIFICATIONS
Page 8
CHASSIS: 11 GA- rectangular tube
BODY:
Two piece - made of rotational molded polyethylene. Front body contains
Model ZTR 5423
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. Seat is adjustable fore and aft.
MOWER DECK:
13 GA stamped steel construction 3 blades combine for a 42"
cut width Cut height approximately 1 .5" to 4.5" via 7 position
lift handle
BLADE DRIVE:
DRIVE SYSTEM:
Electric clutch
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:
18 HP Kohler Command, 4-Cycle, V-Configuration, Overhead Valve, AirCooled, Gasoline, Horizontal and 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.
STARTING SYSTEM:
TIRES:
RECOMMENDED
TIRE PRESSURE:
CAPACITIES:
DIMENSIONS:
Electric by key switch operation with safety interlocks on parking brake and blade
drive clutch.
Front 11 X 4 X 5 smooth profile
Rear 18 X 9.5 X 8 Multi Trac
Front 16-21lbs.
Rear 8-14lbs.
Fuel - 4.8 gallons total (dual tanks) Hydrostat oil tank 3 quart with in-line 10 micron filter Hydrostat oil
recommendation, refer to page 37 Engine - 2 qts. SAE
10W30 (with filter)
Width 51"
Height 45"
Length 72"
Weight 615lbs.
NOTE: Additional information provided in service instructions under
the individual component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
SPECIFICATIONS
CHASSIS:
BODY:
SEAT:
MOWER DECK:
BLADE DRIVE:
DRIVE SYSTEM:
ENGINE:
Model ZTR 5502
1 1 GA - rectangular tube
Two piece - made of rotational molded polyethylene. Front body contains
access panels for battery service and engine to mower deck belt removal. Rear
body tilts up to allow service on the entire drive system.
Economically designed for operator comfort by use of high density closed cell
foam, contoured back rest and arm rests. Seat is adjustable fore and aft.
1 1 GA fabricated welded construction with external reinforcement ribs 3
blades combine for a 50" cut width Cut height approximately 1 .5" to
4.5" via 8 position lift handle
Electric clutch
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.
20HPKohler Command, 4-Cycle,V-Configuration, Overhead Valve, Air-Cooled,
Gasoline, Horizontal and 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.
STARTING SYSTEM:
TIRES:
RECOMMENDED
TIRE PRESSURE:
CAPACITIES:
DIMENSIONS:
NOTE:
Electric by key switch operation with safety interlocks on parking brake and blade
drive clutch.
Front 11X4X5 smooth profile
Rear 20 X 10 X8 Multi Trac
Front 16-21 Ibs.
Rear 8 -14 Ibs.
Fuel - 4.8 gallons total (dual tanks) Hydrostat oil tank 3 quart with in-line 10 micron filter Hydrostat oil
recommendation, refer to page 37 Engine - 2 qts. SAE
1 0W30 (with filter)
Width 60"
Height 45"
Length 72"
Weight 680 Ibs.
Additional information provided in service instructions underthe individual
component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
Page 9
SPECIFICATIONS
Page 10
CHASSIS: 11 GA - rectangular tube
BODY:
SEAT:
MOWER DECK:
BLADE DRIVE: Electric clutch
DRIVE SYSTEM:
ENGINE:
Two piece - made of rotational molded polyethylene. Front body contains
access panels for battery service and engine to mower deck belt removal. Rear
body tilts up to allow service on the entire drive system.
Ergonomically designed for operator comfort by use of high density closed cell
foam, contoured back rest and arm rests. Seat is adjustable fore and aft.
1 0 GA stamped steel construction 3 blades combine for
60" cut width Cut height approximately 1 " to 4" via 8
position lift handle
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.
22HP Kohler Command, 4-Cycle, V-Configuration, Overhead Valve, Air-Cooled,
Gasoline, Horizontal and 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.
Model ZTR 5601
STARTING SYSTEM:
TIRES:
RECOMMENDED
TIRE PRESSURE:
CAPACITIES:
DIMENSIONS:
NOTE:
Electric by key switch operation with safety interlocks on parking brake and blade
drive clutch.
Front 11X4X5 ribbed tread
Rear 20 X 1 0 X 8 Multi Trac
Front 16-21lbs.
Rear 8-14lbs.
Fuel - 4.8 gallons total (dual tanks) , Hydrostat oil tank
- 3 quart with in-line 1 0 micron filter Hydrostat oil
recommendation, refer to page 37 Engine - 2 qts. SAE
10W30 (with filter)
Width 72"
Height 45"
Length 72"
Weight 685 Ibs.
Additional information provided in service instructions underthe individual
component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
SEAT ADJUSTMENT INSTRUCTIONS
Models ZTR 5423 - ZTR 5502 - ZTR 5601 :
1 . Place parking brake in ON position. (Pull brake lever up)
2. Raise and push seat assembly and upper body rearward.
3. Loosen two front seat adjustment knobs, P/N 3978, and slide seat forward or backward to
desired position.
4. Re-tighten front seat adjustment knobs, P/N 3978.
DO NOT operate mower without seat adjustments properly tightened.
5. Carefully lower upper body and seat assembly to the closed position.
CARRIAGE BOLT
Page 11
CONTROLS
Page 12
PARKING BRAKE:
The parking brake used on the 5000 Series Models is designed to
hold the mower from moving and is not intended for use in stopping
the mower while it is in motion.
CAUTION Engage parking brake before starting engine.
Do not leave engine running for extended periods of time
without the parking brake engaged. Damage to the drive
system could result.
CONTROLS
TO SET PARKING BRAKE:
The hand operated parking brake is located at left hand side of
mower.
To engage brake, pull lever up and to the rear.
To release brake, move lever forward and 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).
Drive levers control braking, turning, travel speed and direction. Each lever controls one
side of the mower.
NOTE: The pressure required to operate the mower is very light.
A minimum of 1/2 hour should be spent simply driving the mower
without the blade drive engaged.
Page 13
TO GO FORWARD:
From neutral position, gently push both drive levers forward.
To increase speed, move levers farther forward.
TO GO BACKWARD:
CONTROLS
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:
To brake mower, move both levers in direction opposite of travel, release levers to
neutral, 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 14
BLADE DRIVE:
Located on control panel, on operator's right.
To engage the mower blades, lift switch up
lightly and push forward.
To disengage blades, pull switch backward.
Switch is clearly marked "on and off".
CIRCUIT BREAKER:
Located on control panel, on operator's right.
CONTROLS
Protection of the electrical system is by
(1)15 amp circuit breaker.
If circuit breakertrips, 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, Model ZTR 5422.
Eight positions of adjustment, Model ZTR 5502 &
Model ZTR 5601.
Move lever in and forward to lower.
Move lever in and back to raise.
NOTE: Always use high position for transport.
Page 15
OPERATION INSTRUCTIONS
The safe and successful operation of the 5000 Series Models will depend upon the operator
having the correct knowledge of all controls used on the mower and making good judgements
about the terrain to be mowed.
NEVER allow anyone to operate the mower without complete knowledge of all controls and
their functions.
During initial operation, "learning to drive", set throttle at slow speed.
Sound judgement by the owner will prevent accidents.
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. Check gas cap to be sure it is in place.
6. Be sure parking brake is on.
7. Mower blade drive is off.
8. Know how to stop engine. (Turn key to off position)
Page 16
TESTING OF SAFETY INTERLOCK SYSTEMS:
OPERATION INSTRUCTIONS
PARKING BRAKE SWITCH TEST:
With parking brake in the OFF position,
engine should not turn over or attempt to
start when the key switch is moved to
the start position.
BLADE DRIVE SWITCH TEST: (5000 Series)
a. With electric blade drive switch turned ON
and parking brake in the ON position,
engine should not turn over or attempt to
start when key switch is moved to the start
position.
b. In a SAFE AREA away from bystanders,
start the engine, place throttle setting at
maximum or full. Engage the blades by
turning the blade drive switch to the ON
position. Raise weight slightly off of seat.
Engine should stop.
c. 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 17
OPERATION INSTRUCTIONS
STARTING INSTRUCTIONS: Cold Engine
1. Push choke control lever fully forward.
2. Push throttle control lever to 1/2 setting.
3. Insert ignition key and turn to "Start" position. When engine starts,
release ignition key. Key will return to "Run" position.
4. Once engine starts to warm up, slowly move choke control lever to the
fully closed position.
5. Move throttle control lever to the wide open or maximum setting for actual
operation of the mower deck.
6. Engine must be operated at wide open or maximum setting to insure
adequate lubrication, cooling and cut quality of the mower deck.
NOTE: Model ZTR 5601 will
require a slightly longer
warm up period using
partial choke settings.
Page 18
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