Dixon ZTR 5000 Series 2000 Operator`s 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 ............................. ................. ........
WARRANTY POLICY ............................. ........
SPECIFICATIONS ................................. ........
SEAT ADJUSTMENT ............................. ........
CONTROLS .......................................... ........
OPERATION INSTRUCTIONS ............... ........
CARE AND MAINTENANCE ................... 22
........
STANDARD SERVICE PARTS LIST ....... . ....
TROUBLESHOOTING ............................ 40
........
Part No. 8965
5/98
Pages 2Page
8
Page
9
Page
Pages 11-14
Pages 15Pages 23Page 39Paaes 41-
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.
Page 2
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 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
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:
Page 4
The Engine Exhaust from this product contains chemicals known to the
State of California to cause cancer, birth defects or other reproductive harm.
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.
Page 5
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.
Page 6
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 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 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: 11 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
Electric clutch
BLADE DRIVE:
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
Rear
RECOMMENDED
TIRE PRESSURE:
Front
Rear
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
Height
Length
Weight
NOTE:
Additional information provided in service instructions under the individual component
11 X 4 X 5 ribbed tread
20 X 10 X 8 Multi Trac
16-21 Ibs.
8 -14 Ibs.
51 "(42" Deck), 60"(50" Deck), 72"(60" Deck)
45"
72"
615 lbs.(42" Deck), 680 lbs.(50" Deck), 685 lbs.(60" Deck)
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
Page 9
SEAT ADJUSTMENT INSTRUCTIONS
Model ZTR 5022:
1.
Set parking brake.
2.
Raise upper body.
3.
Loosen two front seat
adjustment knobs and slide
seat forward or backward tc
desired position.
4.
Re-tighten front seat
adjustment knobs.
DO NOT
operate mower
without seat adjustments
properly tightened.
5.
Carefully lower upper body
and seat assembly to the
closed position.
Page 10
Page 11
CONTROLS
5000 Series
CONTROLS
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.
parking brake before starting
CAUTION Engage
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
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).
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.
Page 12
CONTROLS
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.
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 13
BLADE DRIVE:
CONTROLS
Located on control panel, on operator's right.
1998 Models
To engage blades: Slide switch to rear and flip
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
amp circuit 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.
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 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
TESTING OF SAFETY INTERLOCK SYSTEMS:
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 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.
A CAUTION
NOTE:
DO NOT operate the engine in an enclosed area due to the
harmful exhaust gas produced.
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.
Page 18
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 Sharp Blades Throughout The Cutting Season. This is very important. Optimal
mulching performance cannot be obtained with dull or nicked blades.
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!
'
Page 19
OPERATION INSTRUCTIONS
MOWING WITH A GRASS CATCHER ATTACHMENT:
In order to achieve optimum performance when mowing with a grass catching attachment, please read
and follow the tips listed below:
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 both the underside of the deck
and the attachment chutes. Empty bags often to prevent plugging.
3.
If the grass is tall, place the mower deck cut height selector in the top or second notch. Initially
overlap cutting swaths instead of a full swath with each pass.
4.
Keep The Underside Of The Mower Deck Clean. Frequent removal of dried grass and dirt will
greatly assist in bagging of the clippings.
5.
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.
Maintain Sharp Blades Throughout The Cutting Season.
7.
Operate the mower at a slower ground speed than when mowing without a grass catching
attachment.
•
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.
•
Disengage blade and stop engine prior to clearing grass from either the discharge chute or grass
catcher 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 20
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 on page 40.
Be sure that deflector is properly installed on the
dischargechute.
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 discharge area.
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.
Grass Types:
Zoysia
Blue Grass
Fescue Blends
St. Augustine (Mid South)
St. Augustine (Deep South)
Tifton Bermuda
Centipede
Common Bermuda
Bahia/Argentina/Pensacola
Best Cut Heights:
2" - 2 1/2"
1 1/2" - 3"
1 1/2" - 3"
1 1/2" - 2"
3" - 4"
1 1/2"
1 1/2" - 2"
1 1/2" - 2"
2"
Page 21
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 22
CARE AND MAINTENANCE
This portion of the 5000 Series Models owners manual deals with normal service items which can be
performed by the owner. Please remember that if you are in doubt as to the correct service procedures
to be followed, these and other service situations can be handled by a Dixon ZTR dealer who is familiar
with the service of your mower.
MAINTENANCE SCHEDULE:
To insure a long and trouble free service life on all the components used on the 5000
Series Models, a regular and thorough maintenance 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.
7.
8.
Drive system, belts and controls.
Mower deck belts.
Tire pressures.
HydroGear oil tank.
Tightness of all nuts and bolts.
Battery fluid level.
* Engine oil. (Before each use or every 8 hours)
Electric blade clutch air gap setting.
Before performing any maintenance,
shut off engine, allow to cool.
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 BATTERY STORAGE:
Identify each cable so cables can be reconnected to correct terminals.
Disconnect cables from terminals.
ALWAYS disconnect ground cable first and reconnect last.
Charge battery.
DO NOT remove battery from mower.
Clean top of battery and terminals with baking soda and water.
Page 23
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.
Wear heavy, thick gloves when holding onto mower blade, avoid
the sharp edqe of the b|ade.
4. Tighten blade nut securely. Refer to diagram.
NOTE: Be sure blade is centered on pilot before tightening bolt to 60 ft. Ibs. torque.
Page 24
CARE AND MAINTENANCE
ENGINE TO MOWER DECK BELT:
42' and 50"
P/N 6111
60"
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"
P/N 6109
50"
P/N 1300
60"
P/N 6939
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 25
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 26
CARE AND MAINTENANCE
5000 SERIES 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 27
CARE AND MAINTENANCE
HOT oil may cause burns.
Allow engine to cool before draining oil.
CHANGING THE ENGINE OIL:
1. The "snap lock" 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. Push the valve body in and twist to clear the detent notch.
4. Pulling the valve body outward will start the flow of oil.
NOTE:
Refer to engine manufacturers recommendations for frequency of oil changes.
OIL FILL:
1. Push the valve body in and twist into the detent notch.
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:
Engine oil changes on the 5000 Series Models will require replacement of the oil
filter. These filters can be obtained from any authorized Kohler engine dealer.
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 38 are the correct part numbers for each engine in the
5000 Commercial Series.
PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS
PROTECT YOUR ENVIRONMENT
Page 28
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
positon. Belt can now be removed from mower deck pulley.
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 29
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. Place the mower on a smooth level surface, check tire pressures to insure the mower
has a correct 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. Measure from the floor surface up to the bottom of the blade tip on the discharge side
of the mower deck. Retain this measurement. Move to the opposite side, check that
measurement is the same. If adjustment is required, turn the nut on the bottom of
the front 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, blade tips should be level to 1/8" higher than side to side
measurement. In the front, blade tips should be level to 1/8" lower than side to side
measurement.
NOTE:
Page 30
This will place the mower deck in a base measurement position. Additional
adjustment may be required to achieve desired cut for the type of grass or
conditions being mowed.
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 31
CARE AND MAINTENANCE
PARKING BRAKE CABLE ADJUSTMENT:
Make necessary adjustments to the T-Box to Hydrostat belt, as shown on page 30.
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:
Page 32
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.
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 parking 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)
c. turn control rod in or out until neutral is achieved
d. tighten jam nuts on control rod
e. tighten bolt in control tube
4. Engage parking brake and lower the body.
Release parking brake and swing control levers in. If wheel creeps, repeat step 3.
4. Stop engine and remove rear of machine from jack or blocks.
Page 33
CARE AND MAINTENANCE
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.
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 levers are now uneven at top speed, loosen control lever mounting nut. Rotate lever to be even
with other side and tighten nut.
Page 34
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. Remove the clutch from the engine. This is recommended because it is easier to verify the
gap.
2. Locate the three rivet joints which fasten the leaf springs to
the armature, (figure 1)
3. Rotate the pulley until these rivet joints are located midway
along the edge of the triangular field adapter, (figure 1)
4. Locate the three holes in the brake plate, one near each
adjustment nut. (figure 2)
5. 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 3)
6. 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 feeler gauge cannot be reinserted after removal.
7. Repeat Steps 5 and 6 at the other two windows.
8. Re-check the air gap at each window and make minor
adjustments as necessary to achieve a consistent
.012 inch air gap.
9. Reinstall the clutch to the engine. Be sure to torque the
mounting bolt back to 50 ft. Ibs.
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.
5. If the clutch coil is faulty, the clutch must be replaced.
Page 35
CARE AND MAINTENANCE
HYDROSTATIC TRANSMISSION OIL AND FILTER SERVICE
SERVICE INTERVALS:
1 . Initial oil and filter service - 50 hours.
2. Every 250 hours thereafter.
OIL REQUIREMENTS:
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:
Page 36
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.
CARE AND MAINTENANCE
HYDROSTATIC TRANSMISSION OIL AND 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 37
CARE AND MAINTENANCE
WHEELS AND TIRES:
Correct tire pressure is important for correct operation of
mower.
Air Pressure 16-21 Ibs. (Front)
Air Pressure
8-14 Ibs. (Rear)
NOTE: Check lug nuts periodically for tightness.
ELECTRICAL SYSTEMS:
Keep all connections clean and tight.
CLEANING THE MOWER:
Wash mower periodically.
Clean above and below deck.
NOTE:
Allow mower to cool before washing. If bearings are
hot, they will draw moisture inside as they dry and
cause corrosion.
SERIAL NUMBERS:
The serial number is located on frame at rear of engine.
WARRANTY:
Refer to Warranty Registration Form (P/N 8289).
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 38
STANDARD SERVICE PARTS LIST
42" DECK
BLADES:
LoLift:
P/N 6236
Standard Hi-Lift:
P/N8688
Engine To Mower Deck:
Serpentine Belt:
Engine To T-Box:
Engine To T-Box:
T-Box To Hydros:
Grass Blower Belt:
P/N6111
P/N6109
P/N 171 4(1 998 models)
P/N 7253(1 999 models)
P/N 1765
P/N 4983
Lo Lift:
P/N 9443
Standard Hi-Lift:
P/N 9444
Engine To Mower Deck:
P/N 6111
Serpentine Belt:
Engine To T-Box:
Engine To T-Box:
T-Box To Hydros:
Grass Blower Belt:
P/N 1300
P/N 1714(1998 models)
P/N 7253(1 999 models)
P/N 1765
P/N 4983
BLADES:
Hi-Lift:
P/N 9445
BELTS:
Engine To Mower Deck:
P/N 6938
Serpentine Belt:
Engine To T-Box:
Engine To T-Box:
T-Box To Hydros:
P/N 6939
P/N 1714(1998 models)
P/N 7253(1 999 models)
P/N 1765
BELTS:
K5 '
50" DECK
BLADES:
BELTS:
60" DECK
Page 39
STANDARD SERVICE PARTS LIST
KOHLER 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.
Model ZTR 5022:
Page 40
22HP
Pre-Cleaner Foam Element
Cartridge Air Cleaner
Engine Oil Filter
45083-01
45083-02
12050-01
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.
The Troubleshooting Chart suggests practices and adjustments that may be helpful in
improving cut quality. Your Dixon ZTR dealer is also available to provide assistance to you.
SITUATION
CAUSES
REMEDY
Poor cut quality
Ground speed
Reduce mowing speed
Poor cut quality
Incorrect engine to
mower deck belt
Refer to page 38 for part numbers
Poor cut quality
Engine RPM too low
Increase engine RPM to maximum
Poor cut quality
Dull or bent blade
Sharpen or replace as required
Poor cut quality
Un-level mower deck
Refer to page 29 for deck leveling
procedure
Poor cut quality
Grass buildup under
mower deck
Clean out underside of mower deck
Poor cut quality
Improper blades
Refer to page 38 for part numbers.
Poor cut quality
Uneven tire pressures
Refer to page 37 for correct tire
pressures.
Page 41
TROUBLESHOOTING
DRIVE SYSTEM:
SITUATION
CAUSES
REMEDY
Mower pulls to one
side or the other
Forward travel
speed adjustment
Refer to page 33 for procedure or
consult your dealer for repair
Drive system will not
function on either side
after changing hydrostatic
transmission oil and filter
Incorrect oil filter installed
on system
Hydrostatic transmissions
are "air locked", low or no
oil return to tank
Replace with correct Dixon filter
Consult your dealer for repairs
Continued attempted operation
may result in damage to the
system
Drive system functions
on one side only
Loss of set screw tension Consult your dealer for repairs
on hydrostatic
transmission pulley
Loss of power and speed
on both hydrostatic
transmissions
Incorrect parking brake
cable adjustment
Incorrect or worn drive
belt
Refer to adjustment procedure
page 31 or consult your dealer
for repair
Replace with correct belt
Mower creeps in
neutral position
Neutral adjustment
Refer to adjustment procedure page
32 or consult your dealer for repair
Page 42
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
turn engine over
Dead battery
Charge battery
Battery discharge
Poor connections on
battery
Battery water low Wrong
battery installed in
mower
Tighten or replace as required
Battery discharge
Engine electrical system
not functioning correctly
Have electrical system checked by
your dealer
Battery discharge
Engine being operated
at too low an RPM
Increase engine RPM Contact your
dealer for information
NOTE: Electrical system failures are generally simple in nature, always check the obvious
first and then move onto the more complicated parts used. Poor battery service,
loose connections, corrosion, frayed or broken wiring, are more likely than component
failure.
Page 43
NOTES
DIXON INDUSTRIES, INC. A
BLOUNT International Inc.Co.
PO BOX 1569
COFFEYVILLE KS 67337 0945
316251 2000
OWNER
INFORMATION
Engine Exhaust from this product contains chemicals known to the
WARNING: The
State of California to cause cancer, birth defects or other reproductive
harm.
®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
3162512000
5000 Series
Part No. 8965
5/98