Dixon 13089-0601 Lawn Mower User Manual
Contents
1. consult dealer Parking brake not on ngage parking brake ENGINE WILL TURN OVER BUT WON T START No fuel refuel and or clean or replace fuel filters HARD TOSTART ENGINE Fuel line clogged clean fuel line and check fuel filter Faulty fuel pump consult dealer ENGINE STARTS BUT CUTS OUT Water in fuel drain old fuel replace with new fuel Clogged fuel line check fuel filter Fuel tank vent plugged clean fuel vent Faulty fuel pump check vent ENGINE OVERHEATED Air intake screen or fins clogged clean intake screen and fins Oil level too low or too high adjust oil level Running engine too slow run engine faster 10 TROUBLESHOOTING ENGINE RUNS BUT MOWER W ON T MOVE FORWARD Drive belt broken or slipping replace drive belt Transmission oil low add oil Transmission locks in free wheel position lock position see pg 20 Hydrostat oil filter plugged replace filter Bad transmission consult dealer Gear mating transmission gearbox disconnected consult dealer MOWER LOSES POWER OR TRANSMISSION OVERHEATS Hydrostat belt loose 2 c2. CARE AND MAINTENANCE CAUTION Before performing any maintenance turn off engine allow to cool amp remove key Use extreme care when working on machinery Do not wear watch or jewelry Do not wear loose fitting clothes and observe all common safety practices with tools MAINTENANCE SCHEDULE eAdjust traction drive Idler after 5 hours break in eCheck deck Serpentine Delt sess after 20 hours break in adjust bumper to approximately 1 2 thick eCheck crankcase Oil IOV cece settee teteneseeteteataeeees before each use eClean grass from hydrostat fans eecseeceeeeeeeeeeeees before each use eClean grass amp debris from muffler amp manifold area before each use Clean grass under COCK ceccceseeeseeeseeteteteeeesseeteeteeaneneiens after each use eCheck tire PrOSSUPC hn ccsseesesceestseesesesteteteseecetenssesteteeaeatenees every 10 hours eInspect blades for Sharpness eeeeeeneey every 10 hours eCheck hydrostatic transmission flUIC ees eeeseseeeeeeeeees every 25 hours eClean air filter element eee cece tetenteteteteesneenteieeee every 25 hours eCheck traction drive idler adjustment every 50 hours see page 48 Grease All ZerkKS ns esesseesssecsecsseeseeeseesneeseeeseesteentesseesteesteateeseeesteeseenenaes every 50 hours Check all balsa ara every 50 hours Change engine crankcase oil and filter 5 hours break in every 50 hours Replace air filter elements sssri annually or every 1
3. 20 OPERATION INSTRUCTIONS The safe and successful operation of the 5000 Series 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 the controls and their functions During initial operation learning to drive set throttle at slow speed TOWING Towing a trailer or other attachment that is too heavy could damage the drive or cause the mower to become unstable Limit loads to 500 pounds or less with this mower 21 OPERATION INSTRUCTIONS BEFORE OPERATING MOWER 22 1 Read and observe all safety instructions on your mower and in the manual Read engine manufacturer s operating and maintenance instructions Discuss proper maintenance with your dealer Check engine oil Check fuel cap to be sure it is in place Be sure parking brake is on Be sure mower blade drive is off Know how to stop engine Turn key to off position OPERATION INSTRUCTIONS A TESTING OF SAFETY INTERLOCK SYSTEMS Do not operate mower if safety switches are not operating properly PARKING BRAKE SWITCH TEST a Place parking brake in OFF position b Turn ignition switch to START ENGINE SHOULD NOT TURN OVER OR ATTEMPTTO START BLADE DRIVE SWITCH TEST a Place parking brake in ON position b Engage blade drive switch c Turn ignition sw
4. of free pa parking brake released or drive belt may slip causing loss of power 48 CARE AND MAINTENANCE 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 ofcontrol 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 5 Tighten lug nuts to a minimum torque factor of 50 ft lbs 49 CARE AND MAINTENANCE NEUTRAL ADJ USTMENT 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 paking brake 3 Raise the upper bodyto 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 cont
5. 685 Ibs 60 Deck Additional information provided in service instructions under the individual component SPECIFICATIONS SUBJ ECT TO CHANGE WITHOUT NOTICE 13 CHASSIS BODY SEAT MOW ER DECK BLADE DRIVE DRIVE SYSTEM ENGINE STARTINGSYSTEM TIRES RECOM M ENDED TIRE PRESSURE CAPACITIES DIMENSIONS SPECIFICATIONS Model ZTR 5023 11 GA rectangular tube 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 Designed for operator comfort by use of high density closed cell foam padded back and arm rests upholstered with Cordura water repellent fabric Seat is adjustable fore and aft Two decks are available The 60 is made of stamped steel The 50 is made of 11 GA fabricated welded construction with external reinforcement ribs Three blades combine for a 50 or 60 cut width Cut height approximately 1 5 to 4 5 via 7 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 23HP 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
6. Pump Fixed J et Carburetor w Smart Choke Electronic Ignition In Line Fuel Filter Dual Element Air Cleaner Electric by key switch operation with safety interlocks on parking brake and blade drive clutch Front 11 X 4 5 Ribbed Tread Rear 20 X10 8 Multi Trac Front 16 21 lbs Rear 8 14 lbs Fuel 4 8 gallons total dual tanks Hydrostat oil tank 3 quart with inline 40 micron filter Engine 2 qts SAE 10W30 with filter Width 60 50 Deck 72 60 Deck Height 45 Length 72 Weight 680 lbs 50 Deck 685 lbs 60 Deck Additional information provided in service instructions under the individual component SPECIFICATIONS SUBJ ECT TO CHANGE WITHOUT NOTIFICATION 14 SEAT ADJ USTMENT INSTRUCTIONS 5000 Series Models 1 Grasp seat slide adjuster and move it into adjustment position 2 Slide seat forward or backward 3 Release seat slide adjuster a F Ae SEAT SLIDE ADJUSTER 15 CONTROLS CONTROL LEVERS Note NEUTRAL abate FAST For access to the seat move control levers to neutral position and swing them outward TO GO FORW ARD From neutral position gently push both control levers forward eTo increase speed move levers further forward TO GO BACKW ARD eFrom neutral position gently pull both control levers toward you TURNING eTurning is controlled by moving one control lever slightly forward or rearward of the other eTo turn left move left lever rearward of the r
7. a pins as illustrated below 3 Slide deck from beneath chassis 4 Reverse procedure to re install deck to chassis 46 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 ADJ USTMENT Tighten the 2 bolts on the T box mounting plate until each belt has 1 8th to 1 4th of free play or move ment 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 spring must be positioned to depress the bypass relief pins Remove bypass keeper springs prior to actual operation of the mower 47 CARE AND MAINTENANCE PARKING BRAKE CABLE ADJ USTMENT Make necessary adjustments to the T Box to Hydrostat belt as shown on page 47 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 of free play If adjustment is required turn the lock nut illustrated below to achieve a recommended 1 1 2 to 2 of free play NOTE Cable must have the recommended 1 1 2 to 2
8. 00 hours Replace spark PlUGS cece annually or every 100 hours eChange hydrostat oil and oil filter 100 hours break in every 500 hours 33 CARE AND MAINTENANCE ENGINE For complete maintenance and operating information ofthe engine please refer to the maintenance instructions furnished bythe engine manufacturer and included in your Zero Turn Radius mower informa tion packet BATTERY Battery contains sulfuric acid electrolyte which is A CAUTION poisonous and corrosive eThis is a maintenance free battery and the fluid level cannot be checked Charge battery if required OFF SEASON BATTERY STORAGE DO NOT remove battery from mower Clean top of battery and terminals with baking soda and water eldentify each cable so they can be reconnected to the correct terminal Disconnect cables from terminals ALWAYS disconnect ground cable first and reconnect last Charge battery TIRES Correct tire pressure is essential for efficient operation of the mower Checktire pressure periodically Inflate tires to the pressure listed below FrontTires 11x4 005 16 21 lbs PSI Rear Tires 20x10 50 8 8 14 lbs PSI Lug nuts or lug bolts should be checked regularly for tightness 34 CARE AND MAINTENANCE CUTTER BLADE MAINTENANCE A CAUTION Stop engine and remove ignition key for safety W ear heavy thick gloves when holding onto cutter blade avoid the sharp edge of the blade Check sharpness o
9. DIXO 5000 SERIES lt pu Z lt gt x gt lt fala IMPORTANT READ CAREFULLY The Dixon 9 ZTR Mower is both easy and fun to operate However any power mower must be operated properlyto be safe It is not a toy or a recreational vehicle Before you start to use the mower read the operator s manual carefully and become completely familiar with the controls The information contained in this manual applies to all Dixon 9 ZTR 5000 Series Mowers Your Dixon dealer will gladly answer any questions See your dealer for warranty service parts and repairs INDEX Page A C ye ii Sit sees Rak tee Raat Sarde a sees 4 11 W arranty POMC Vac nenas e ute soe alba da ale ines ad 12 SPECINCALONS a a ais wean 13 14 Seat Adjustment Instructi0NS ooooooooo o 15 CONOS riirn reir dada datada 16 20 Operation Instructi0NS 21 32 Care amp Maintenance o oooooooo 3354 Standard Service Parts Listo sion 55 Troubleshooting 5 2 63245 oc Pre 56 57 5000 Series Part No 13089 0601 Ah SAFETY RIDING LAWN MOWERS IF IMPROPERLY OPERATED CAN CAUSE SERIOUS INJ URY OR DEATH The most common causes of injury to the operator or bystander BLADE CONTACT TIP OVER RUN OVER BACK OVER fead and understand this manual to prevent injuries Ad SAFETY A Safety Alert Symbol W hen you see this symbol BE AL
10. ER ATTACHMENT In order to achieve optimum performance when mowing with a grass catching attachment please read and follow the tips listed below 30 Set engine speed control to the wide open or full setting Allow engine mower deck and blower to reach full RPM before attempting to mow Do Not Attempt To Cut Grass When It Is W et Wet grass will clog both the underside of the deck and the attachment chutes Empty bags often to prevent plugging 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 Keep The Underside Of The M ower Deck Clean Frequent removal of dried grass and dirt will greatly assist in bagging of the clippings Use onlythe correct blade s Some grass catching attachments require a high lift blade See your dealer for advice on the type of blade s needed for your mower Maintain Sharp Blade s Throughout The Cutting Season OPERATION INSTRUCTIONS MOWING WITH A GRASS CATCHER ATTACHMENT continued Operate the mower at a slower ground speed than when mowing without a grass catching attachment Some mowing applications use of grass catchers may require that an optional weight box be fitted to the mower to counter the weight of grass in the bags Please consult with your dealer for more information regarding installation and adding weight to the box CAUTION W atch for low h
11. ERT to the potential for injury Follow recommended safety precautions and safe operating practices DANGER A DANGER highlighted in red indicates an imminently hazardous EN situation which if not avoided will result in death or serious injury WARNING AWAR N l NG highlighted in orange indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION highlighted in yell A CAUTION neste ea hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices Ad SAFETY Failure to observe the following safety instructions could result in serious injury or death GENERAL OPERATION Read understand and follow all instructions in the manual and on the mower before starting Only allow responsible adults who are familiar with the instructions to operate the mower Clear the area of objects such as rocks toys wire etc which could be picked up and thrown by the blade Be sure the area is clear of other people before mowing Stop mower if anyone enters the area NEVER carry passengers Do not mow in reverse unless absolutely necessary Always look down and behind before and while backing Be aware of the mower discharge direction and do not point it at anyone Do not operate the mower without either the entire grass catcher or the deflector in place Slow down before turning N
12. FF VALVE The fuel shut off valve is located at the bottom rear of the fuel tank Always turn the valve to the OFF position when the mower is stored or not in use ON OFF LUBRICATION CHASSIS 5 grease zerks used 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 Once per season or 50 hours of operation 3 pumps each Note Adequate lubrication ofthe caster tubes and mower deck hubs will help dispel moisture from within the bearing retention areas Bearings are of a sealed variety 37 CARE AND MAINTENANCE Hot oil may cause burns Allow A CAUTION engine to cool before draining oil CHANGING THE ENGINE OIL 1 The Dapco oil drain valve is located on the left side of the engine crankcase 2 Place a Suitable container under the drain valve The fitting of a short piece of hose will help direct the oil 3 To drain turn hex head valve stem counter clockwise with 10mm wrench or socket Open to full open approximately 7 turns 4 After engine is drained tighten hex stem NOTE Refer to engine manufacturer s recommendations for frequency of oil changes Hex Head Valve Stem 38 CARE AND MAINTENANCE OIL FILL 1 Drain oil 2 Clean any spilled oil from engine and chassis 3 Refill engine with type and quantity of oil recommended bythe engine manufac
13. ION INSTRUCTIONS OPERATION INSTRUCTIONS STARTING INSTRUCTIONS cold engine he Position choke control in on position 2 Position throttle control at fo lo 1 2 speed setting Ti 3 Insert ignition key and turn to oe start position When ee engine Starts release CHOKE THROTTLE ignition key Key will return to run position 4 Onceenginestartstowarm oaa up Slowly move choke x control to off position aN A Oe o cuts O LIGHTS 5 Move throttle control to the fast position 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 A CAUTION Do not operate the engine in an enclosed area due to the harmful exhaust gas produced 27 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 ei
14. ZTR 5020 11 GA rectangular tube Two piece made of rotational molded polyethylene Front body contains access panels for battery service amp engine to mower deck belt removal Rear body tilts up to allow service on the entire drive system Designed for operator comfort by use of high density closed cell foam padded backrest and arm rests upholstered with Cordura water epellent fabric Seat is adjustable fore and aft Two decks are available The 60 is made of stamped steel The 50 is made of 11 GA fabricated welded construction with external reinforcement ribs Three blades combine for either a 50 or 60 cut width Cut height approximately 1 5 to 4 5 via 7 position lift handle Electric clutch Each rear wheel is independently driven bya HydroGear BDU 10L Series 70 hydrostatic transmission The hydrostatic transmissions power a fully enclosed HydroGear gearbox 20HP Briggs amp Stratton ELS overhead valves replaceable oil filter full pressure lube system dual element air cleaner integral fuel pump Electric by keyswitch operation with safety interlocks on parking brake and blade drive clutch Front 11 X 45 ribbed tread Rear 20 X10 8 Multi Trac Front 16 21 lbs Rear 8 14 lbs Fuel 4 8 gallons total dual tanks Oil tank 3 quart with inline 40 micron filter Engine 2 qts SAE 30 with filter W idth 60 50 Deck 73 60 Deck Height 45 Length 72 Weight 668 Ibs 50 Deck
15. ake before moving mower eAllows the mower to turn on its own axis zero turning radius Each lever controls one side of the mower Note The pressure required to operate the mower is very light CONTROLS BLADE DRIVE eLocated on control panel to operator s right op Jo To engage blade Pull up on switch To disengage blade Push down CIRCUIT BREAKER eLocated on control panel to operator s right Protection of the electrical system is by 1 15 amp circuit breaker elf circuit breaker trips push button to reset elf this condition repeats consult dealer for inspection and repair MOWER DECK CUT HEIGHT LIFT LEVER eLocated 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 19 CONTROLS TO FREEWHEEL MACHINE UNLOCK TRANSMISSION Move end of by pass keepers to depress plunger at rear of each hydro pump Release parking brake To engage the transmission move by pass keepers so plungers return to their normal positions NOTE Before pushing or towing tractor transmission must be unlocked and parking brake released The tractor should never be pulled at more than 2 miles per hour or for any appreciable distance
16. anging 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 bag 31 OPERATION INSTRUCTIONS DECK ROLLERS 60 deck 32 Purpose Height Adjustment Lubrication 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 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 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 The use of a penetrating oil or light grease on the roller bracket shafts will keep roller moving freely
17. brake plate one near each adjustment nut Figure 1 3 Insert a 012 feeler gauge into one of the three windows Be careful to position the feeler gauge between the rotor and armature faces Figure 2 4 Tighten the adjustment 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 ae the feeler gauge cannot be reinserted after removal 5 Repeat steps 5 and 6 at the other two windows 6 Recheck the air gap at each window and make minor adjustments as necessary to achieve a consistent 012 air gap Figure 1 52 CARE AND MAINTENANCE PROCEDURE FOR ELECTRIC CLUTCH ADJ USTMENT CONTINUED B OHMS TEST I 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 5 to 4 0 OHMS 4 If the resistance is outside this range the clutch coil is faulty 5 Ifthe clutch coil is faulty the clutch must be replaced Figure 2 53 CARE AND MAINTENANCE FORWARD TRAVEL SPEED ADJ USTMENT 1 Drive machine on a smooth 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 Ro
18. cancer birth defects or other reproductive harm Dixon and ZTR O are registered trademarks of Dixon Industries Inc DIXON INDUSTRIES INC a BLOUNT International Inc Co P 0 Box1569 5000 Series Coffewille Ks 67337 0945 5020 amp 5023 620 251 2000 Part No 130890601
19. cccssaedeiesd eden ss adjust see page 48 Hydrostat transmission oil too low or high add or drain oil Transmission damage consult dealer Transmission blowing oil out cap overfilled or water contaminated ENGINE STALLS WHEN BLADES ARE ENGAGED Operator not on Seat sit on seat Faulty interlock system consult dealer Bad Blade spindle bearing consult dealer Deck drive belt not properly routed 4 reroute Blades blocked by foreign material clean under deck DRIVE SYSTEM Low ON poWer check belt tension Mower pulls to side check tire inflation adjust control linkage Mower creeps in neutral adjust control linkage CUT QUALITY Skips in spots check for loose belt slow ground speed Cut uneven left to right check tire inflation level the deck Poor dispersal of grass clean deck check for loose belt Ends of grass blades are ragged Sharpen blades 57 58 NOTES OWNER INFORMATION DIXON INDUSTRIES INC a BLOUNT International Inc Co P 0 Box1569 Coffeyville Ks 67337 0945 620 251 2000 FAX 620 251 4117 Date Purchased DIXO ZTROM owers The engine exhaust from this product contains chemicals known A WA R N N G tothe State of California to cause
20. ck up the slope or if you feel uneasy on it do not mow it Mow across the slope with your Dixon ZTR never up or down Remove obstacles such as rocks tree limbs etc Watch for holes ruts or bumps Uneven terrain could overturn the mower Tall grass can hide obstacles Use slow speed Tires may lose traction on slopes even though the brakes are functioning properly Use extra care with grass catchers or other attachments These can change the stability of the mower Keep all movement on the slopes slow and gradual Do not make sudden changes in speed or direction Avoid starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly down the slope If front wheels lift off the ground pull the levers back to stabilize the mower Do not 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 Ad 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 aler
21. easurements are equal Retain measurement CARE AND MAINTENANCE MOWER DECK LEVELING PROCEDURE continued D Turn both outer blades to align with the deck in frontto rear manner Turn left rear adjuster nut up or down until rear of mower deck is positioned level to 1 8 higher in the rear than the sideto side measurement At this time the mower deck will be suspended on 3 points both front adjusters and the left rear adjuster M ove the right rear adjuster and take out the slack which will be present byturning adjuster locknut 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 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 Front Adjusters Left Rear Adjuster Deck Leveling Adjustment Points 45 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 M ove lift handle into the lowest cut position Belt can now be removed from mower deck pulley Insert end of link here 5283 Link Front of lift frame 2 Remove front and rear fleck
22. ever leave a running mower unattended Always turn off blades set parking brake stop engine and remove key before dismounting Ah SAFETY GENERAL OPERATION continued Turn off blades when not mowing Stop engine before removing grass catcher or unclogging chute M ow only in daylight or good artificial light Do not operate the mower while under the influence of alcohol or drugs W atch 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 and unloading Always wear safety goggles or safety glasses with side Shields when operating mower Data indicates that operators age 60 years and above are involved in a large percentage of riding mower elated injuries These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury Follow the manufacturer s recommendation for wheel weights and counterweights Maintain or replace safety amp instruction labels as needed The engine exhaust from this product contains chemicals known to the WARNING State of California to cause cancer birth defects or other reproductive harm 7 Ad SAFETY SLOPE OPERATION Slopes are a major factor related to loss of control and tip over accidents DO which can result in severe injury or death All slopes require extra caution If you cannot ba
23. f mower blades after every 10 hours of operation Observe proper blade position prior to removal 1 Safelyraise front of mower Ze Hold or block blade from turning 3 Loosen blade nut and remove blade 4 W hen replacing blade tighten blade nut securely A Refer to diagram Be sure WASHER ay blade is centered on pilot NUTS he before tightening nut to 60 ft Ibs Blades should be discarded when worn excessively DANGEROUS 25 DO NOT USE pe BLADE IN THIS New Blade gt CONDITION When notch starts discard blade 35 CARE AND MAINTENANCE BELTS Check belts every 50 hours Replace any belts found to be in poor condition BELT TENSION Engine to M ower Deck Belt P N 6111 50 P N 6938 60 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 P N 1300 50 P N 6939 60 Refer to illustration for adjustment procedure Idler W eldment Hex Nut Idler Shock Mount L Rod 2 J 2000 5 8 Tighten or loosen hex nut to achieve this demension E Note Belt deflection or movement should be approximately 1 4 when measured at mid point between pulleys Periodically inspect both belt and idler systems 36 CARE AND MAINTENANCE FUEL SHUT O
24. fuel dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Do not use a nozzle lock open device Ah SAFETY SERVICE continued Never run a mower inside a closed area The exhaust fumes are toxic Keep nuts and bolts tight especially blade attachment bolts and keep equipment in good condition Never tamper with safety devices Check their proper operation regularly Keep mower free of grass leaves or other debris buildup Clean up oil or fuel spillage Allow mower to cool before storing Stop and inspect the equipment if you strike an object Repair if necessary before restarting Never make adjustments or repairs with the engine running unless otherwise specified Grass catcher components are subject to wear damage and deterioration which could expose moving parts or allow objects to be thrown Frequently check components and replace with Original equipment parts when necessary M ower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing them Batteries contain sulfuric acid To prevent burns avoid contact with skin eyes and clothing To prevent a fire or explosion keep sparks and open flames away from battery Before disconnecting the negative ground cable make sure all switches are OFF 11 DIXON INDUSTRIES INC aBLOUNT company Airport Industrial Park P 0 Bo
25. ight lever eTo turn right move right lever rearward of the left lever To turn on mower s own axis zero turning radius stop and move one lever to reverse position and the other to forward position BRAKING eTo brake mower move both levers in direction opposite of travel MAA VOD O SLOW FORWARD FORWARD RIGHT REVERSE TURN LEFT TURN OPPOSITE Note The pressure required to operate the mower Is very light 16 CONTROLS CHOKE CONTROL LEVER eLocated on control panel to operator s right Used to start a cold engine THROTTLE CONTROL LEVER eLocated on control panel to operator s right Controls engine speed slow to maximum eW hile moving throttle control should be set to MAXIMUM for wide open setting to insure adequate cooling ofthe engine and to maintain mower deck blade speed Y ae it L JA CTE C ut N j oK THROTTLE 17 CONTROLS PARKING BRAKE The parking brake is designed to hold the mower from moving and is not intended for use in stopping the mower while it is in motion A HYDRO GEAR SYSTEM 18 CAUTION Engage parking brake before starting engine TO SET PARKING BRAKE The hand operated brake is located at the left hand side of the mower To engage brake pull lever up to the rear To release brake move lever forward down Note Always set parking brake before dismounting Release parking br
26. itch to START ENGINE SHOULD NOT TURN OVER OR ATTEMPT TO START SEAT SWITCH TEST a Ina SAFE AREA away from bystanders start the engine b Engage blade drive switch c Raise slightly off seat ENGINE SHOULD STOP If any safety check fails Do not operate the mower until the system has been checked and repaired by an authorized Dixon ZTR dealer 23 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 CAUTION Be sure that the deflector is properly installed on the discharge chute Ty Set engine speed control to the wide open or full setting Ze Do Not Attempt To Cut Grass When It Is Wet W et 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 M ower Deck Clean Frequent removal of dried grass and dirt will allow the clippings to discharge correctly 5 Maintain Sharp Blade s Throughout The Cutting Season 24 OPERATION INSTRUCTIONS GRASS HEIGHT AND CUTTING SUGGESTIONS Do not attempt to cut grass when it is wet If the grass is tall place the m
27. orrosion SERIAL NUMBERS The serial number is located on frame at rear of engine WARRANTY See W arranty Registration Form P N 8288 sample on page 12 PARTS SERVICE See your Dixon dealer for replacement parts warranty or service PLEASE HELP PROTECT THE ENVIRONMENT BY AVOIDING ALL CHEMCIALS WHICH MAY DAMAGE OR CAUSE HARM TO PLANTS AND ANIMALS IN YOUR AREA 43 CARE AND MAINTENANCE MOWER DECK LEVELING PROCEDURE 44 There are a total of 4 threaded adjusters which will control the attitude or pitch ofthe mower deck The adjusters have locknuts 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 NOTE To insure accuracy of leveling procedure mower deck drive belt must be installed prior to leveling deck B Wear heav gloves 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 M ove 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 m
28. ower 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 Keep the underside of the mower deck clean Maintain sharp blades throughout the cutting season As arule of thumb never cut off more than 1 3 of the total grass blade length 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 build up 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 Best Cut Heights Bermudagrass 1 2 Bluegrass 2 3 Buffalograss 112 3 Ryegrass 2 3 Tall Fescue 3 312 Zoysiagrass 1 3 25 STARTING INSTRUCTIONS engine has been operated 26 1 Move throttle controlto 1 4 to 1 2 setting Insert ignition key and turn to start position W hen engine starts release ignition key Key will return to run position Move throttle control to fast position Note Model5023 may require partial choke setting to start even if the engine has been operated for a period oftime 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 OPERAT
29. rol rod in or out until neutral is achieved d tighten jam nuts on control rod e tighten bolt in control tube 9067 CONTROL ROD NA ADJUST IN STEP C Na 5540 CONTROL TUBE JAM NUTS LOOSENIN lt gt STEP B TIGHTEN IN STEP D CONTROL TUBE BOLT LOOSEN IN STEP A TIGHTEN IN STEP E 50 CARE AND MAINTENANCE NEUTRAL ADJ USTMENT continued 4 Engage parking brake and lower the body Release parking brake and swing control levers in If wheel creeps repeat step 3 5 Stop engine and remove rear of machine from jack or blocks 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 CONTROL LEVER MOUNT ING NUT a ADJUST POSITION TO CHANGE FORWARD RANGE OF CONTROL lt EVER IF NECESSARY 51 CARE AND MAINTENANCE PROCEDURE FOR ELECTRIC CLUTCH ADJ USTMENT 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 AD USTMENT 1 It is not necessary to remove the clutch from the motor 2 Locate the three holes in the
30. s 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 cutting blades Hydro Gear filters d Engines All engines used on Dixon ZTR mowers are warranted bythe 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 Blue Customer Yellow Dealer White Dixon Ind WARRANTY VALIDATION At the time of sale selling dealer must review each portion of this warranty document complete the information section below secure customer s signature and send copy to Dixon Industries Inc DATE OF PURCHASE MODEL SIN Owners Name Dealership sssi lt isi s s z lt CS Address si s sSsSSCS Address sss lt sSSSSSCS Owner s Signature Dealer s Signature 12 CHASSIS BODY SEAT MOW ER DECK BLADE DRIVE DRIVE SYSTEM ENGINE STARTING SYSTEM TIRES RECOM M ENDED TIRE PRESSURE CAPACITIES DIM ENSIONS SPECIFICATIONS Model
31. t 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 10 Ad SAFETY Use extra care in handling gasoline and other fuels They are flammable and vapors are explosive Use onlyan approved container Never remove fuel cap or add fuel with engine running Allow engine to cool before refueling Do not smoke while refueling Never refuel the mower indoors Never store the mower or fuel container inside a building where there is an open flame If fuel is spilled on clothing change clothing immediately To prevent fire and explosion caused by static electricity Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner Always place containers on the ground awayfrom your vehicle before filling W hen practical remove fuel powered equipment from the truck or trailer and refuel it on the ground If this is not possible then refuel such equipment on a trailer with a portable container rather than from a fuel dispenser nozzle If a
32. tate lever to be even with other side and tighten nut ADJUST POSITION TO CHANGE ORWARD RANGE OF CONTROL LEVER IF NECESSARY 54 STANDARD SERVICE PARTS LIST Blades Belts Blades Belts 50 Deck Hi Lift P N 9444 Standard Lo Lift P N 9443 Engine to Mower Deck P N 6111 Serpentine P N 1300 Engine to T Box P N 7253 T Boxto Hydros P N1765 Grass Blower Belt P N 4983 60 Deck P N 9445 Hi Lift Engine to Mower Deck P N 6938 Serpentine Belt P N 6939 Engine to T Box P N 7253 T Boxto Hydros P N1765 BRIGGS amp STRATTON AND KOHLER AIR amp OIL FILTER PART NUMBERS Refer to engine manufacturers manual for correct service intervals for engine oil changes and air filter maintenance Protect your engine investment use only original equipment filters Kohler 5023 B amp S 5020 Air Filter Pre Cleaner Kit P N 78002 Engine Oil Filter P N 78006 Air Filter Pre Cleaner Kit P N 79003 Engine Oil Filter P N 79006 55 56 TROUBLESHOOTING ENGINE W ON T TURN OVER Mower blades engaged disengage blades Drive not in neutral move control levers to neutral OUT Circuit breaker tripS reset breaker Dead battery charge or replace Solenoid consult dealer Ignition switch consult dealer Starter
33. ther the top or second notch Never cut more than 3 4 to 1 off the grass at anyone 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 Blade s Throughout The Cutting Season This is very important Optimal mulching performance cannot be obtained with a dull or nicked up blade 28 OPERATION INSTRUCTIONS MOWING WITH A MULCHING ATTACHMENT continued 6 Keep the Underside Of The M ower Deck Clean Remove all grass and dirt build up 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 It may be necessary to cut your grass more frequently Operate the mower at a slower ground speed Overlap cutting swaths instead of cutting a full swath with each pass Mow across the marginal areas a second time CUT HIGH MOW OFTEN 29 OPERATION INSTRUCTIONS MOWING WITH A GRASS CATCH
34. to drain from oil return hoses into container When oil flowing from hoses is clear and contains no bubbles stop the engine 9 Re attach 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 full mark 41 CARE AND MAINTENANCE HYDROSTATIC TRANSMISSION OIL FILTER SERVICE Dirt or water in oil can ruin the hydrostatic transmissions SERVICE INTERVALS 1 Initial filter service 50 hours 2 Every250 hours or once a year thereafter OIL REQUIREMENTS Any high quality engine oil with an API classification of SG CD is recommended RECOM MENDED OIL W EIGHT Normal operation temperatures 20W 50 Cold climate usage 10W 40 Another alternative that will provide excellent all climate performance and extended time between oil changes is a 15W50 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 DONOT Use automotive engine oil filters These filters require a pressure to allow oil flow Usage will result in an airdock condition with possible damage 42 CARE AND MAINTENANCE 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 c
35. turer in engine literature OIL FILTERS 1 Replace filter each time the oil is changed 2 These filters can be obtained from your authorized engine dealer Briggs amp Stratton P N 492 932 Kohler P N 12 050 01 5 3 The use of any other oil filter may cause damage to the engine PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS PROTECT YOUR ENVIRON MENT 39 CARE AND MAINTENANCE HYDROSTATIC TRANSMISSION OIL FILTER SERVICE 40 If transmission is to be serviced proper air purging procedures must be followed or damage will occur 1 Remove oil filter from chassis allowing oil to drain into container Clean impurities from inside of reservoir If necessary 2 Fill new filter with oil not doing so can cause air pocket in system and possible hydro damage Install new oil filter to chassis Use only genuine Dixon replacement oil filter Using any other brand of oil filter may not be internally compatible and could cause damage to hydrostat transmission 3 Put fresh oil in reservoir Fill reservoir to full mark 4 Remove two oil return hoses from top of oil reservoir and direct these hoses into a container for oil draining CARE AND MAINTENANCE HYDROSTATIC TRANSMISSION OIL FILTER SERVICE continued 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
36. x1569 Coffeyville Ks 67 337 0945 620251 2000 Fax620 251 4117 DIXON LIMITED WARRANTY POLICY ESTATE MODELS 5000 Series WARRANTY Home Owner Application This Dixon Warranty term is for a period of two 2 years from date of purchase Commercial Application Dixon mowers used for commercial application are warranted for one 1 year from the date of purchase or 400 hours whichever comes first Commercial use is specified as use other than or in addition to mowing at owner s primary place of residence 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 SUBJ ECT TO THE FOLLOW ING CONDITIONS AND LIMITATIONS 1 Warranty applies only to original retail purchaser of new amp 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 Batterywarranty Limited to 90 days from date of purchase 4 Accessories W arranty Grass Catchers Snow Blades Covers etc Limited to 90 days from date of purchase 5 Warranty does not apply to damage in transit or incidents of misuse negligence accidents or alteration The use of parts or components other than those supplied by Dixon Industries Inc VOIDS ALL WARRANTY 6 The following items are not covered by thi
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