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
Commercial Mowers. Your Dixon dealer will gladly answer any questions.
See your dealer for warranty service, parts and repairs.
DIXON INDUSTRIES, INC.
A BLOUNT International Inc. Co.
PO BOX 1569
COFFEYVILLE KS 67337 0945
316 251 2000

INDEX
SAFETY
.............................
.................
........
Pages 2
-
WARRANTY POLICY ............................. ........ Page 8
SPECIFICATIONS ................................. ........ Page 9
SEAT ADJUSTMENT
.............................
........
Page
CONTROLS .......................................... ........ Pages 11-14
OPERATION INSTRUCTIONS ............... ........
Pages 15
-
22
CARE AND MAINTENANCE
...................
........
Pages 23
-
STANDARD SERVICE PARTS LIST ....... .
....
Page 39
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40
TROUBLESHOOTING
............................
........
Paaes 41
-
Part No. 8965
5/98

SAFETY
RIDING LAWNMOWERS, IF IMPROPERLY OPERATED,
CAN CAUSE SERIOUS INJURY OR DEATH
The most common causes of injury to the operator or bystander...
...read and understand this manual to prevent injuries.
Page2

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 3
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. Do not ride the
mower when loading & unloading.
WARNING: The Engine Exhaust from this product contains chemicals known to the
Stateof Californiato causecancer, birthdefects orother reproductiveharm.
Page 4

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.
Useslow 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 losetraction, 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.
Page5

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.
Page6

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 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.
Page 7

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 to90 days from date of purchase.
4. Accessories Warranty (Grass Catchers, Snow Blades, Tine Rakes, Covers, etc.): Limited to90 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 / 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.
Page8

SPECIFICATIONS
Model ZTR 5022
CHASSIS: 11 GA -rectangular tube
BODY: Two piece -made of high-density polyethylene. Front body contains access
panels for battery service and engine to mower deck belt removal. Rear body
tilts up to allow service on the entire drive system.
SEAT: Economically designed for operator comfort, contoured back rest and arm
rests. Seat is adjustable fore and aft.
MOWER DECK: 42" Deck: 13 GA Stamped Steel Construction -42" Cut Width
50" Deck: 1
1 GA Fabricated Construction/Reinforcement Ribs
-
50" Cut Width
60" Deck: 1 0 GA Stamped Steel Construction
-
60" Cut Width
Cut height approximately 1 " to 4" via 7 position lift handle
BLADE DRIVE: Electric clutch
DRIVE SYSTEM: Each rear wheel is independently driven by a HydroGear BDU-10L Series 70
hydrostatic transmission. The hydrostatic transmissions, in turn, power a fully
enclosed HydroGear gearbox.
ENGINE: 22HP Kohler Command, 4-Cycle, V-Configuration, Overhead Valve, Air-Cooled,
Gasoline, Vertical Shaft, Aluminum Head, and Crankcase with Cast Iron Liners,
Full Pressure Lubrication/Full Flow Filter, Pulse-type Fuel Pump, Fixed Jet
Carburetor w/Smart-Choke, Electronic Ignition, In-Line Fuel Filter, Dual Element
Air Cleaner.
STARTING SYSTEM: Electric by key switch operation with safety interlocks on parking brake and
blade drive clutch.
TIRES: Front 11 X4X5 ribbed tread
Rear 20 X 10 X 8 Multi Trac
RECOMMENDED Front 16-21 Ibs.
TIRE PRESSURE: Rear 8 -14 Ibs.
CAPACITIES: Fuel -4.8 gallons total (dual tanks)
Hydrostat oil tank
-
3 quart with in
-
line filter
Hydrostat oil recommendation, refer to page 35
Engine -2 qts. SAE 10W30 (with filter)
DIMENSIONS: Width 51 "(42" Deck), 60"(50" Deck), 72"(60" Deck)
Height 45"
Length 72"
Weight 615 lbs.(42" Deck), 680 lbs.(50" Deck), 685 lbs.(60" Deck)
NOTE: Additional information provided in service instructions under the individual component
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
Page 9

SEAT ADJUSTMENT INSTRUCTIONS
Model ZTR 5022:
1. Setparking brake.
2. Raise upper body.
3. Loosen two front seat
adjustment knobs and slide
seat forward or backward tc
desiredposition.
4. Re-tightenfront seat
adjustment knobs.
DO NOT
operate mower
without seat adjustments
properly tightened.
5. Carefully lower upper body
and seat assembly to the
closedposition.
Page 10

5000 Series
CONTROLS
Page 11

CONTROLS
PARKING BRAKE:
The parking brake used on the 5000 Series Models is designed to hold
the mower from moving and isnot intended for use in stopping the
mower while it is in motion.
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.
TO SET PARKING BRAKE:
The hand operated parking brake is located at left hand side
ofmower.
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
beforemoving mower.
HYDRO-GEAR DRIVE SYSTEM:
Allows the mower to turn on its own axis (zero turning radius).
Control 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.
First-time operators should spend a minimum of 1/2 hour driving the mower
without the blade drive engaged to become familiar with the controls.
CAUTION
Page 12

CONTROLS
TO GO FORWARD:
From neutral position, gently push both drive levers forward.
To increase speed, move levers fartherforward.
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.
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 orwide open setting to
insure adequate cooling of the engine and to maintain mower deck blade speed.
Page13

BLADE DRIVE: CONTROLS
Located on control panel, on operator's right.
1998 Models
To engage blades:Slide switch to rear andflip
up and forward.
To disengage blades:Flip switch down.
1999 Models
To engage blades:Pull switch up.
To disengage blades:Push switch down.
CIRCUIT BREAKER:
Located on control panel, on operator's right.
Protection of the electrical system is by (1)15
ampcircuit breaker.
If circuit breaker trips, push button to reset.
If this cpndition 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.
Depresstrigger andmove leverforward tolower
deck.
Depress trigger and pull lever back to raisedeck.
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
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.
First-time operators should set throttle at slow speed while learning to drive.
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. Be sure mower blade drive is off.
8. Know how to stop engine. (Turn key to off position)
Page 15

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.
TESTING OF SAFETY INTERLOCK SYSTEMS:
Page 16

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 for actual operation of the
mower deck.
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.
Page 17

OPERATION INSTRUCTIONS
STARTING INSTRUCTIONS: Engine has been operated.
1. Move throttle control to 1/4 to 1/2 setting.
2. Insert ignition key and turn to "Start" position. When engine starts,
release ignition key. Key will return to "Run" position.
3. Move throttle control to FAST position for actual operation of the mower
deck.
NOTE: Model ZTR 5022 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.
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.
A CAUTION
Page 18