Page 2 - IMPORTANT - READ CAREFULLY
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 operators manual carefully and become completely familiar with the ...
Page 3 - INDEX; Page
3 INDEX Page Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-14 Seat Adjustment Instructions. . . . . ...
Page 4 - The most common causes of injury to the operator or bystander...; BLADE CONTACT; SAFETY
4 RIDING LAWN MOWERS, 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. BLADE CONTACT TIP OVER RUN OVER BACK OVER SAFETY
Page 5 - Safety Alert Symbol; When you see this symbol,; Follow recommended safety precautions
5 Safety Alert Symbol When you see this symbol, BE ALERT to the potential for injury. DANGER (highlighted in red) indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING (highlighted in orange) indicates a potentially hazardous situation whi...
Page 9 - Tragic accidents can occur if the operator is
9 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 un...
Page 12 - DIXON LIMITED WARRANTY POLICY - HYDRO GEAR MODELS
12 WARRANTY: Dixon Commercial Warranty is for a period of one (1) year from date of purchase or 400 hours of use, whichever occurs first. Mowers used for Homeowner Application (used only at owners primary place of residence) are warranted for two (2) years from date of purchase. DIXON ZTR MOWERS AR...
Page 13 - SPECIFICATIONS
13 SPECIFICATIONS Model ZTR 5004/5005 CHASSIS: 11 GA - rectangular tube BODY: Two piece-made of rotational molded polyethylene. Front body contains access panels for battery service & engine to mower deck belt removal. Rear body tilts up to allow service on the entire drive system. SEAT: Designe...
Page 15 - SEAT ADJUSTMENT INSTRUCTIONS; Grasp seat slide adjuster and move
15 SEAT ADJUSTMENT 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.
Page 16 - CONTROLS; CONTROL LEVERS; Note: The pressure required to operate the mower is very light.
16 CONTROLS CONTROL LEVERS Note: For access to the seat, move control levers to neutral position and swing them outward. TO GO FORWARD: • From neutral position, gently push both control levers forward. • To increase speed, move levers further forward. TO GO BACKWARD: • From neutral position, gently ...
Page 17 - THROTTLE CONTROL LEVER:
17 CONTROLS CHOKE CONTROL LEVER: • Located on control panel to operators right. • Used to start a cold engine. THROTTLE CONTROL LEVER: • Located on control panel to operators right. • Controls engine speed, slow to maximum. • While moving, throttle control should be set to MAXIMUM for wide open se...
Page 18 - CAUTION
18 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. CAUTION Engage parking brake before starting engine. TO SET PARKING BRAKE: The hand operated brake is located at the left hand side of the m...
Page 19 - MOWER DECK CUT HEIGHT LIFT LEVER:; NOTE: Always use high position for transport.; CIRCUIT BREAKER
19 CONTROLS 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 ...
Page 20 - TO FREE WHEEL MACHINE; Always turn off engine before engaging or disengaging
20 CONTROLS TO FREE WHEEL MACHINE (UNLOCK TRANSMISSION): Always turn off engine before engaging or disengaging the hydro release (free wheel) valves. Never attempt to move the by-pass keeper with the engine running. Move end of by-pass keepers to depress plunger (valve) at rear of each hydro pump. R...
Page 21 - OPERATION INSTRUCTIONS; NEVER
21 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 ...
Page 22 - BEFORE OPERATING MOWER:
22 BEFORE OPERATING MOWER: 1. Read and observe all safety instructions on your mower and in the manual. 2. Read engine manufacturers operating and maintenance instructions. 3. Discuss proper maintenance with your dealer. 4. Check engine oil. 5. Check fuel cap to be sure it is in place. 6. Be sure p...
Page 23 - TESTING OF SAFETY INTERLOCK SYSTEMS:; ENGINE SHOULD NOT TURN OVER
23 OPERATION INSTRUCTIONS 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 ATTEMPT TO START! BLADE DRIVE SWITCH ...
Page 24 - SIDE DISCHARGE OF THE CLIPPINGS:
24 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...
Page 25 - GRASS HEIGHT AND CUTTING SUGGESTIONS:
25 OPERATION INSTRUCTIONS GRASS HEIGHT AND CUTTING SUGGESTIONS: Do not attempt to cut grass when it is wet. 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...
Page 26 - STARTING INSTRUCTIONS
26 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. Note: Model 5023 may req...
Page 28 - MOWING WITH A MULCHING ATTACHMENT:; Do Not Attempt To Cut Grass When It Is Wet.
28 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 recycl...
Page 29 - MOWING WITH A MULCHING ATTACHMENT; Keep the Underside Of The Mower Deck Clean.
29 OPERATION INSTRUCTIONS MOWING WITH A MULCHING ATTACHMENT (continued): 6. Keep the Underside Of The Mower 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 gra...
Page 30 - MOWING WITH A GRASS CATCHER ATTACHMENT:
30 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. Allow engine, mower deck and blower to r...
Page 31 - MOWING WITH A GRASS CATCHER ATTACHMENT
31 OPERATION INSTRUCTIONS MOWING WITH A GRASS CATCHER ATTACHMENT (continued): 7. Operate the mower at a slower ground speed than when mowing without a grass catching attachment. 8. Some mowing applications/use of grass catchers may require that an optional weight box be fitted to the mower to counte...
Page 33 - MAINTENANCE SCHEDULE
33 CARE AND MAINTENANCE CAUTION CAUTION CAUTION CAUTION CAUTION Bef Bef Bef Bef Before perf ore perf ore perf ore perf ore perfo r o r o r o r o r ming an ming an ming an ming an ming any maintenance y maintenance y maintenance y maintenance y maintenance, tur , tur , tur , tur , tur n off engine n ...
Page 34 - CARE AND MAINTENANCE
34 CARE AND MAINTENANCE ENGINE: For complete maintenance and operating information of the engine, please refer to the maintenance instructions furnished by the engine manufacturer and included in your Zero Turn Radius mower informa- tion packet. BATTERY: • This is a maintenance-free battery and the ...
Page 35 - CUTTER BLADE MAINTENANCE:
35 CARE AND MAINTENANCE CUTTER BLADE MAINTENANCE: CAUTION Stop engine and remove ignition key for safety. Wear heavy, thick gloves when holding onto cutter blade, avoid the sharp edge of the blade. Check sharpness of mower blades after every 10 hours of operation. Observe proper blade position prior...
Page 36 - Check belts every 50 hours. Replace any belts found to be in; Engine to Mower Deck Belt:; The engine to mower deck drive belts are automatically held; Mower Deck Serpentine Belt:; Refer to illustration for adjustment procedure.
36 CARE AND MAINTENANCE BELTS: Check belts every 50 hours. Replace any belts found to be in poor condition. BELT TENSION: Engine to Mower Deck Belt: P/N 6111 (42 & 50) P/N 6938 (60) The engine to mower deck drive belts are automatically held in proper tension by springs which push the deck as...
Page 38 - CHANGING THE ENGINE OIL:
38 Hex Head Valve Stem Hot oil may cause burns. Allow engine to cool before draining oil. CAUTION CARE AND MAINTENANCE CHANGING THE ENGINE OIL: 1. The Dapco oil drain valve is located on the right side of the engine crankcase on the 5004 & 5005 and on the left side of the engine crank- case on...
Page 39 - The use of any other oil filter may cause damage
39 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 by the engine manufacturer in engine literature. OIL FILTERS: 1. Replace filter each time the oil is changed. 2. These filters can be obtained...
Page 40 - HYDROSTATIC TRANSMISSION OIL & FILTER SERVICE:
40 HYDROSTATIC TRANSMISSION OIL & FILTER SERVICE: 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 ...
Page 41 - HYDROSTATIC TRANSMISSION OIL & FILTER SERVICE
41 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 to drain from oil return hoses into cont...
Page 42 - Dirt or water in oil can ruin the hydrostatic transmissions.
42 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. Every 250 hours or once a year thereafter. OIL REQUIREMENTS: Any high quality engine oil with an API clas...
Page 44 - MOWER DECK LEVELING PROCEDURE:
44 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 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 ...
Page 45 - NOTE
45 CARE AND MAINTENANCE MOWER DECK LEVELING PROCEDURE (continued): 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 1/8 higher in the rear than the side-to-side measurement. At this time,...
Page 48 - PARKING BRAKE CABLE ADJUSTMENT:; Make necessary adjustments to the T-Box to Hydrostat
48 CARE AND MAINTENANCE PARKING BRAKE CABLE ADJUSTMENT: 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 bel...
Page 49 - Slopes are a major factor related to loss-of-control and
49 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-of-control and tip-over accide...
Page 52 - PROCEDURE FOR ELECTRIC CLUTCH ADJUSTMENT:
52 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...
Page 53 - PROCEDURE FOR ELECTRIC CLUTCH ADJUSTMENT
53 CARE AND MAINTENANCE PROCEDURE FOR ELECTRIC CLUTCH ADJUSTMENT (CONTINUED): 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 2.5 to 4.0 OHMS. 4. If the ...
Page 54 - FORWARD TRAVEL SPEED ADJUSTMENT:
54 CARE AND MAINTENANCE FORWARD TRAVEL SPEED ADJUSTMENT: 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...
Page 55 - TROUBLESHOOTING
55 1 . ENGINE WONT TURN OVER Mower blades engaged- - - - - - - - - - - - - - - - - - - - - - -disengage blades Drive not in neutral - - - - - - -move control levers to neutral OUT Circuit breaker trips- - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - reset breaker Dead battery- - - -...
Page 56 - ENGINE RUNS BUT MOWER WONT MOVE FORWARD
56 TROUBLESHOOTING 6. ENGINE RUNS BUT MOWER WONT MOVE FORWARD Drive belt broken or slipping- - - - - - - - - - - - - - - - - - - - replace drive belt Transmission oil low- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - -add oil Transmission locks in free-wheel position- - - - ...
Page 57 - STANDARD SERVICE PARTS LIST
57 STANDARD SERVICE PARTS LIST 42 Deck Blades: Hi-Lift - P/N 8688 (Standard) Lo-Lift - P/N 6236 Belts: Engine to Mower Deck - P/N 6111 Serpentine - P/N 6109 Engine to T-Box - P/N 7253 T-Box to Hydros - P/N 1765 Grass Blower Belt - P/N 4983 50 Deck Blades: Hi-Lift - P/N 9444 (Standard) Lo-Lift - P/...
Page 58 - KAWASAKI AND KOHLER AIR & OIL FILTER
58 STANDARD SERVICE PARTS LIST KAWASAKI AND KOHLER AIR & 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. Kawasaki (5004/5005) Air Fi...
Page 59 - Name
59 OWNER INFORMATION Date Purchased _ ________________________________ Mower Model Number ____________________________ Mower Serial Number ____________________________ Purchased From ___ _____________________________ Name ________________________________ Address ________________________________ DATE...
Page 60 - Dixon® and ZTR® are registered trademarks
ZTR®Mowers ZTR®Mowers ZTR®Mowers ZTR®Mowers ZTR®Mowers Dixon® and ZTR® are registered trademarks of Dixon Industries, Inc. DIXON INDUSTRIES, INC. a BLOUNT International Inc. Co. P.O. Box 1569 Coffeyville, Ks 67337-0945 620-251-2000 5000 Series 5004/5005/5023 Part No. 13634-0702 W W W W WARNING: ARNI...
