Dixon ZTR 5000 Series 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 COMPANY
AIRPORT INDUSTRIAL PARK
PO BOX 1569
COFFEYVILLE KS 67337 O945
316 251 2OOO
FAX [phone]

INDEX
1. SAFETY.................................................................Pages 1-5
2. WARRANTY POLICY...............................................Page 6
3. SPECIFICATIONS..................................................... Page 7-9
4. SEAT ADJUSTMENT ...............................................Page 10
5. CONTROLS...............................................................Pages 11 -14
6. OPERATION INSTRUCTIONS.................................Pages 15 -19
7. CARE AND MAINTENANCE................................. ….Pages 20 -41
8. STANDARD SERVICE PARTS LIST..................... ….Page 42 -43
9. TROUBLESHOOTING..............................................Pages 44-46
10. DIAGRAMS..............................................................Pages 47-65
Part No. 8965
November 1994

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
RUN-OVER
To avoid these and other accidents, read and understand the operator's manual.
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.
SAFETY

SAFETY
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.
Page2

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.
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.

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.
Page4

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.
•Never run a mower inside a closed are*.
•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.

DIXON LIMITED WARRANTY POLICY -- HYDRO-GEAR MODELS
This warranty policy applies to all Hydro-Gear 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 daysfrom 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 / 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 ail 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 Model S/N
DM
"
(Owner's Name) (Dealership)
(Address) (Address)
(Owner's Signature) (Dealer's Signature)
SEE DEALER FOR DETAILS
Page 6

SPECIFICATIONS
Model ZTR 5421
CHASSIS: 11 GA -rectangular tube
BODY: 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.
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: Electric clutch
DRIVE SYSTEM: Each rear wheel is independently driven by a Hydro-Gear BDU-10L Series 70
hydrostatic transmission. The hydrostatic transmissions, in turn, power a fully
enclosed Hydro-Gear gearbox.
ENGINE: 16 HP Kohler Magnum, Vertical Crankshaft, 4-Cycle, Air Cooled, Gasoline, Twin
Cylinder Opposed, Aluminum Crankcase, Removable Cast Iron Cylinder Barrels,
Electronic Ignition, Full Pressure Lubrication.
STARTING SYSTEM: Electric by key switch operation with safety interlocks on parking brake and blade
drive clutch.
TIRES: Front 11 X4 X 5 smooth profile
Rear 18X9.5X8 turf savers
RECOMMENDED Front 16-21lbs.
TIRE PRESSURE: Rear 8-14lbs.
CAPACITIES: Fuel -4.8 gallons total (dual tanks)
Hydrostat oil tank -3 quart with in-line 10 micron filter
Hydrostat oil recommendation, refer to page 40Engine -2
qts. SAE 30 (with filter)
DIMENSIONS: 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
Model ZTR 5501
CHASSIS: 11 GA -rectangular tube
BODY: 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 allowservice on the entire drive system.
SEAT: 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.
MOWER DECK: 12 GA stamped steel construction
3 blades combine for a 50" cut width
Cut height approximately 1.5" to 4.5" via 8 position lift handle
BLADE DRIVE: Electric clutch
DRIVE SYSTEM: Each rear wheel is independently driven by a Hydro-Gear BDU-10L Series 70
hydrostatic transmission. The hydrostatic transmissions, in turn, power a fully
enclosed Hydro-Gear gearbox.
ENGINE: 20 HP Kohler Magnum, Vertical Crankshaft, 4-Cycle, Air Cooled, Gasoline, Twin
Cylinder Opposed, Aluminum Crankcase, Removable Cast Iron Cylinder Barrels,
Electronic Ignition, Full Pressure Lubrication.
STARTING SYSTEM: Electric by key switch operation with safety interlocks on parking brake and blade
drive clutch.
TIRES: Front 11 X 4 X 5 smooth profile
Rear 20 X 10 X 8 turf savers
RECOMMENDED Front 16-21 IDS .
TIRE PRESSURE: Rear 8-14 IDS.
CAPACITIES: Fuel -4.8 gallons total (dual tanks)
Hydrostat oil tank -3 quart with in-line 10 micron filter
Hydrostat oil recommendation, refer to page 40Engine -2
qts. SAE 30 (with filter)
DIMENSIONS: Width 60"
Height 45"
Length 72"
Weight 668 Ibs.
NOTE: Additional information provided in service instructions under the individual
component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
Page 8

SPECIFICATIONS
Model ZTR 5601
CHASSIS: 11 GA -rectangular tube
BODY: 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.
SEAT: 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.
MOWER DECK: 11 GA stamped steel construction
3 blades combine for 60" cut width Cut height approximately
1" to 4" via 8 position lift handle
BLADE DRIVE: Electric clutch
DRIVE SYSTEM: Each rear wheel is independently driven by a Hydro-Gear BDU-10L Series 70
hydrostatic transmission. The hydrostatic transmissions, in turn, power a fully
enclosed Hydro-Gear gearbox.
ENGINE: 22 HP Kohler Command, 4-Cycle, Twin Cylinder, V-Configuration, Overhead
Valve, Air-Cooled, Gasoline, Vertical Shaft, Aluminum Head and Crankcase with
Cast Iron Liners, Oil Cooler.
STARTING SYSTEM: Electric by key switch operation with safety interlocks on parking brake and blade
drive clutch.
TIRES: Front 11X4X5 ribbed tread
Rear 20 X 10 X 8 turf savers
RECOMMENDED Front 16-21lbs.
TIRE PRESSURE: Rear 8-14lbs.
CAPACITIES: Fuel -4.8 gallons total (dual tanks)
Hydrostat oil tank -3 quart with in-line 10 micron filter
Hydrostat oil recommendation, refer to page 40Engine -2
qts. SAE 10W30 (with filter)
DIMENSIONS: Width 72"
Height 45"
Length 72"
Weight 685 Ibs.
NOTE: Additional information provided in service instructions under the individual
component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

SEAT ADJUSTMENT INSTRUCTIONS
Models ZTR 5421 -ZTR 5501 -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.
MODELS ZTR 5501 & ZTR 5601 MODEL ZTR 5421
Page 10

CONTROLS

CONTROLS
The parking brake used on the 5000 Series Models is designed to hold
the mower from moving and is noHntended for use in stopping the
mower while it is in motion.
CAUTION Engage parking brake before starting engine.
Do not leave engine running fo r extended periods of time without the
parking brake engaged. Damage to the drive system could result.
TO SET PARKING BRAKE:
The hand operated parking brake is located at left hand sideof 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.
PARKING BRAKE:
Page 12

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:
To brake mower, move both levers in direction opposite of travel, release levers to neutral,
set parking brake. Park only on level surfaces.
TWIN FUNCTION THROTTLE CONTROL LEVER:
Located on control panel to operators right.
Throttle control for engine speed. ,
Choking for engine starting.
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 while mowing.
CONTROLS:

CONTROLS
BLADE DRIVE:
Located on control panel, on operator's right.
To engage the mower blades, lift switch up
lightly and push forward.
To disengage blades, pull switch backward.
Switch is clearly marked "on and off".
CIRCUIT BREAKER:
Located on control panel, on operator's right.
Protection of the electrical system is by (1)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, Model ZTR 5421.
Eight positions of adjustment, Model ZTR 5501 &
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 14

OPERATION INSTRUCTIONS
The safe and successful operation of the 5000 Series Models will depend upon the operator h aving 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.
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 caps to be sure they are 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)
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.

OPERATION INSTRUCTIONS
STARTING INSTRUCTIONS: Engine has been operated.
1. Move throttle control lever to 1/4 to 1/2 setting.
2. Insert ignition key and turn to "Start" position. When engine starts, release
ignition key. Key will return to "Run" position.
3. Move throttle control lever to wide open or maximum setting for actual operation of
the mower deck.
NOTE: Model ZTR 5601 may require partial choke setting to start even if the
engine has been operated for a period of time.
4. Engine must be operated at wide open or maximum setting to insure adequate
lubrication, cooling and cut quality of the mower deck.
DO NOT operate the engine in an enclosed area due to the
harmful exhaust gas produced.
NOTE: On initial operation, set throttle at slow speed.
Engine cannot be restarted when blade is engaged.
Safety switches stop engine when operator leaves seat while mower
blade is engaged.
Always turn engine off when leaving mower.
Page16
CAUTION

OPERATION INSTRUCTIONS
MOWING WITH A MULCHING ATTACHMENT:
Mulching or recycling the grass clippings requires a totally different mowing approach than would be
normal when side discharging or bagging the grass. There may be instances or conditions where it is not
possible to hide all of the recycled or mulched clippings.
In order to achieve the best results, please read and follow the mulching tips listed below:
1. Set the engine speed control to the wide open or full setting.
2. Place the mower deck cut height selector in either the top or .second notch. Never cut more than
3/4" to 1" off the grass at any one time. Attempting to cut more grass will result in the deck plugging
and cause the engine to stall.
3. It may be necessary to cut the lawn twice to achieve acceptable mulching performance
especially on first cuttings or if the lawn is heavily fertilized.
4. Do Not Attempt To Cut Grass When It Is Wet. Mulching performance will be very poor under wet
grass conditions.
5. Maintain A Sharp Blade Throughout The Cutting Season.This is very important. Optimal
mulching performance cannot be obtained with a dull or nicked blade.
6. 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.
7. 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. Raise the height-of-cut setting on your mower.
2. It may be necessary to cut your grass more frequently.
3. Operate the mower at a slower ground speed.
4. Overlap cutting swaths instead of cutting a full swath with each pass.
5. Mow across the marginal areas a second time.
6. CUT HIGH -MOW OFTEN!