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 operator's manual carefully and become completely familiar with th...
Page 3 - INDEX
Part No. 8965 September 1996 INDEX SAFETY...............................................................Pages 1 - 6 WARRANTY POLICY ..........................................Page 7 SPECIFICATIONS ...............................................Page 8 - 1 0 SEAT ADJUSTMENT................................
Page 4 - The most common causes of injury to the operator or bystander...; BLADE CONTACT
RIDING LAWNMOWERS, IF IMPROPERLY OPERATED, CAN CAUSE SERIOUS INJURY OR DEATH The most common causes of injury to the operator or bystander... TIP-OVER RUN-OVER RUN-OVER Page 1 BLADE CONTACT
Page 5 - will; Warning; could; Caution
SAFETY SYMBOLS: SAFETY ALERT SYMBOL - When you see this symbol, BE ALERT to the potential for injury. Follow recommended safety precautions and safe operating practices. Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Warning indicate...
Page 6 - serious injury or death.
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 al...
Page 7 - DO; Do not
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 ...
Page 8 - • Be alert and turn mower off if a child enters the area.
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 w...
Page 10 - SEE DEALER FOR DETAILS
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 use...
Page 11 - SPECIFICATIONS
SPECIFICATIONS Model ZTR 5423 CHASSIS: 11 GA- rectangular tube BODY: Two piece - made of rotational molded polyethylene. Front body contains access panels for battery service and engine to mower deck belt removal. Rear body tilts up to allow service on the entire drive system. SEAT: Designed for ope...
Page 14 - SEAT ADJUSTMENT INSTRUCTIONS; Raise and push seat assembly and upper body rearward.
SEAT ADJUSTMENT INSTRUCTIONS Models ZTR 5423 - ZTR 5502 - ZTR 5601 : 1 . Place parking brake in ON position. (Pull brake lever up) 2. Raise and push seat assembly and upper body rearward. 3. Loosen two front seat adjustment knobs, P/N 3978, and slide seat forward or backward to desired position. 4. ...
Page 15 - CONTROLS
Page 16 - not; CAUTION; Engage parking brake before starting engine.; TO SET PARKING BRAKE:
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. CAUTION Engage parking brake before starting engine. Do not leave engine running for extended periods of time wi...
Page 17 - THROTTLE CONTROL LEVER:
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 o...
Page 18 - To engage the mower blades, lift switch up; MOWER DECK CUT HEIGHT LIFT LEVER:
CONTROLS BLADE DRIVE: Located on control panel, on operator's right. To engage the mower blades, lift switch up lightly and push forward. To disengage blades, pull switch backward. Switch is clearly marked "on and off". CIRCUIT BREAKER: Located on control panel, on operator's right. Protecti...
Page 19 - OPERATION INSTRUCTIONS; NEVER; BEFORE OPERATING MOWER:; Read engine manufacturer's operating and maintenance
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...
Page 20 - PARKING BRAKE SWITCH TEST:
OPERATION INSTRUCTIONS PARKING BRAKE SWITCH TEST: With parking brake in the OFF position, engine should not turn over or attempt to start when the key switch is moved to the start position. BLADE DRIVE SWITCH TEST: (5000 Series) a. With electric blade drive switch turned ON and parking brake in the ...
Page 21 - STARTING INSTRUCTIONS: Cold Engine; wide open or maximum
OPERATION INSTRUCTIONS STARTING INSTRUCTIONS: Cold Engine 1. Push choke control lever fully forward. 2. Push throttle control lever to 1/2 setting. 3. Insert ignition key and turn to "Start" position. When engine starts, release ignition key. Key will return to "Run" position. 4. Onc...
Page 22 - STARTING INSTRUCTIONS: Engine has been operated.
OPERATION INSTRUCTIONS STARTING INSTRUCTIONS: Engine has been operated. 1. Move throttle control lever to 1/4 to 1/2 setting. 2. Insert ignition key and turn to "Start" position. When engine starts, release ignition key. Key will return to "Run" position. 3. Move throttle control lev...
Page 23 - MOWING WITH A MULCHING ATTACHMENT:; Do Not Attempt To Cut Grass When It Is Wet.
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 ...
Page 24 - MOWING WITH A GRASS CATCHER ATTACHMENT:
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 W...
Page 25 - SIDE DISCHARGE OF THE CLIPPINGS:; and follow the tips listed below.; Be sure that deflector is properly installed on the; Set engine speed control to the wide open or full setting.; GRASS HEIGHT SUGGESTIONS:; Correct mowing height can reduce weeds and disease by 50% to 80%
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 41. Be sure that deflector is properly ins...
Page 27 - CARE AND MAINTENANCE - 5000 SERIES MODELS; MAINTENANCE SCHEDULE:
CARE AND MAINTENANCE - 5000 SERIES MODELS 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 ...
Page 28 - CUTTER BLADE MAINTENANCE:; Observe proper blade position prior to removal.
CARE AND MAINTENANCE - 5000 SERIES MODELS CUTTER 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 cutter blade, avoid the shar...
Page 29 - BELT TENSION; ENGINE TO MOWER DECK BELT:
CARE AND MAINTENANCE - 5000 SERIES MODELS NOTE: Be sure blade is centered on pilot before tightening bolt to 60 ft. lbs. torque. BELT TENSION ENGINE TO MOWER DECK BELT: Models ZTR 5423 & ZTR 5502 P/N 6111 Model ZTR 5601 P/N 6939 The engine to mower deck drive belts are automatically held in prop...
Page 30 - Always; LUBRICATION
CARE AND MAINTENANCE - 5000 SERIES MODELS 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: (7) LOCATIONS: (1) each ...
Page 31 - Remove rear wheel lug nuts and rear wheels.
CARE AND MAINTENANCE - 5000 SERIES MODELS 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 ...
Page 32 - HOT oil may cause burns.; CHANGING THE ENGINE OIL:; hose to the valve will help direct the oil.; PROTECT YOUR INVESTMENT:; PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS
CARE AND MAINTENANCE - 5000 SERIES MODELS 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 fitting of a ...
Page 33 - MOWER DECK INSTALLATION:; a cotter pin and washer. REMOVE AND DISCARD cotter pin and washer
CARE AND MAINTENANCE - 5000 SERIES MODELS MOWER DECK INSTALLATION: NOTE: Brake link (P/N 5283) normally used for installation of engine to mower deck drive belt, has been placed in position during assembly of the lift frame at the factory. For shipment purposes, the brake link has been secured with ...
Page 34 - MOWER DECK LEVELING PROCEDURE:; mower has a correct stance. Inflate tires as required:
CARE AND MAINTENANCE - 5000 SERIES MODELS 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...
Page 36 - PARKING BRAKE CABLE ADJUSTMENT:
CARE AND MAINTENANCE - 5000 SERIES MODELS PARKING BRAKE CABLE ADJUSTMENT: 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 which pulls the idler ...
Page 37 - Swing upper control levers out into the neutral slots.
CARE AND MAINTENANCE - 5000 SERIES MODELS NEUTRALADJUSTMENT: Swing upper control levers out into the neutral slots. Raise upper body to the fully open position. Start engine and disengage parking brake. Caution should be used when releasing parking brake as mower may tend to creep or move prior to a...
Page 38 - FORWARD TRAVEL SPEED ADJUSTMENTS:
CARE AND MAINTENANCE - 5000 SERIES MODELS FORWARD TRAVEL SPEED ADJUSTMENTS: Stop engine, move levers to drive position, lightly push each upper control lever forward until a resistance is felt on the lever. At this time, check that the forward lever stops on the bottom of each lever are hitting the ...
Page 39 - PROCEDURE FOR ELECTRIC CLUTCH ADJUSTMENT
CARE AND MAINTENANCE - 5000 SERIES MODELS PROCEDURE FOR ELECTRIC CLUTCH ADJUSTMENT Electric clutches require periodic Air Gap adjustments to extend the life of the clutch. Listed below is both an Air Gap adjustment procedure and an Ohms test to check for a faulty coil within the clutch. No replaceme...
Page 40 - HYDROSTATIC TRANSMISSION OIL AND FILTER SERVICE; Normal operation temperatures - 20 W 50
CARE AND MAINTENANCE - 5000 SERIES MODELS 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/CC is recommended. RECOMMENDED OIL ...
Page 41 - PLEASE HELP PROTECT THE ENVIRONMENT BY AVOIDING ALL
CARE AND MAINTENANCE - 5000 SERIES MODELS WHEELS AND TIRES: Correct tire pressure is important for correct operation of mower. Model ZTR 5423 Front Tires 11X4X4 Air Pressure 16-21 Ibs. Rear Tires 1 8 X 9.50 X 8 Air Pressure 8-1 4 Ibs. Models ZTR 5502 & ZTR 5601 Front Tires 11X4X5 Air Pressure 16...
Page 42 - STANDARD SERVICE PARTS LIST; Engine To Mower Deck:; Hydrostatic Transmission Filter:
STANDARD SERVICE PARTS LIST MODEL ZTR 5423: BLADES: Standard: Hi-Lift: P/N 6236 P/N 8688 BELTS: Engine To Mower Deck: Serpentine Belt: Engine To T-Box: T-Box To Hydros: Grass Blower Belt: - P/N 6111 P/N 6109 P/N 1714 P/N 1765 P/N 4983 MODEL ZTR 5502: BLADES: Standard: Hi-Lift: P/N 9443 P/N 9444 BELT...
Page 43 - KOHLER AIR AND OIL FILTER PART NUMBERS:; Protect your; Pre-Cleaner Foam Element; OPTIONAL Kohler fresh air filter system.
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 5423:...
Page 44 - TROUBLESHOOTING; SITUATION
TROUBLESHOOTING MOWER CUT QUALITY: There are many variables that can effect 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 th...
Page 66 - DATE PURCHASED MOWER MODEL NUMBER
Dixon Industries, Inc. A International, Inc. Company P.O. Box 1569 Coffeyville, KS 67337-0945 316-251-2000 OWNER INFORMATION DATE PURCHASED MOWER MODEL NUMBER PURCHASED FROM Name Address MOWER SERIAL NUMBER DM- DATE OIL CHANGED: DATE ENGINE TUNED:
Page 67 - NOTES
Page 70 - ® Dixon and ZTR are registered trademarks of Dixon Industries, Inc.
The Engine Exhaust from this product contains chemicals known to 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. Company P.O.Box 1569 Coffeyville...
