Dixon ZTR 5017 User's Manual
Contents
1. ADJUSTHEREFOR PROPER FREE PLAY OF CABLE WITH BRAKE LEVER OFF NOTE Cable musthave the recommended 1 1 2 to 2 inches of free play with parking brake released or drive belt may slip causing loss of power Page 36 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 Raisethe 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 i 9067 CONTROLROD d tighten jam nuts on control rod ADJUST IN STEP C e tighten boltin control tube POM JAM NUTS LOOSEN T INSTEPBTIGHTENIN gt ls STEPD CONTROL TUBE BOLT LOOSENINSTEPA TIGHTENINSTEPE 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 Page 37 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 control2. Depress trigger and pull lever back to raise deck NOTE Always use high position for transport Page 19 OPERATION INSTRUCTIONS Safe and successful operation will depend upon the operator having the correct knowledge of all controls used 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 During initial operation learning to drive setthrottle at slow speed Sound judgement by the operator will prevent accidents DRINK CUP HOLDER located on left rear fender is for transport or carrying ONLY Mower usage requries that both hands be free to control individual levers DO NOT ATTEMPT operation of mower with any type of container or other object in either hand 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 on this mower BEFORE OPERATING MOWER 1 Readengine 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 Checkengine oil 5 Be sure gas cap 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 20 OPERATION INSTRUCTIONS AX TESTING OF SAFETY INTERLOCK SYS
3. 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 Mower Deck Clean Frequent removal of dried grass and dirt will greatly assist in bagging of the clippings 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 Maintain Sharp Blades Throughout The Cutting Season Operate the mower at a slower ground speed than when mowing without a grass catching attachment A CAUTION 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 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 troublesho
4. Check lug nuts periodically for tightness Keep all connections clean and tight 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 The serial number is located on frame at rear of engine Refer to Warranty Registration Form 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 Page 42 ANIMALS IN YOUR AREA STANDARD SERVICE PARTS LIST 42 DECK BLADES BELTS 50 DECK BLADES BELTS 60 DECK BLADES BELTS Lo Lift Standard Hi Lift Engine To Mower Deck Serpentine Belt Engine To T Box T Box To Hydros Grass Blower Belt Lo Lift Standard Hi Lift Engine To Mower Deck Serpentine Belt Engine To T Box T Box To Hydros Grass Blower Belt Hi Lift Engine To Mower Deck Serpentine Belt Engine To T Box T Box To Hydros P N 6236 P N 8688 P N 6111 P N 6109 P N 7253 P N 1765 P N 4983 P N 9443 P N 9444 P N 6111 P N 1300 P N 7253 P N 1765 P N 4983 P N 9445 P N 6938 P N 6939 P N 7253 P N 1765 Page 43 STANDARD SERVICE PARTS LIST KOHLER AND BRIGGS amp STRATTON AIR AND OIL FILTER PART NUMBERS Refer to engine manufacturers manual for recommendations regarding frequency of service required f
5. Inc Co CELA A 5000Series COFFEYVILLE KS 67337 0945 316 251 2000 Part No 8965 0798
6. a pressure to allow oil flow Usage will result in an air lock condition with possible damage Page 40 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 9 Remove oil filter from chassis allowing oil to drain into container Clean impurities from inside of reservoir if necessary Install new oil filter to chassis Use only genuine Dixon replacement oil filter Put fresh oil in reservoir Fill reservoir to the full mark Remove two oil return hoses from top of oil reservoir and direct these hoses into a container for oil draining Depress by pass valve on both hydros Start engine and move throttle to mid range setting Release parking brake 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 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 41 WHEELS AND TIRES ELECTRICAL SYSTEMS CLEANING THE MOWER SERIALNUMBERS WARRANTY PARTS SERVICE CARE AND MAINTENANCE Correct tire pressure is important for correct operation of mower Front Tires 11x4x5 16 21 Ibs Rear Tires 20x10 5x8 8 14 lbs NOTE
7. 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 FRONT WALL OF TUBE FOR MOWER DECK ROLLER BRACKETS 2 PLACES APPLY A THIN COAT OF GREASE Page 26 CARE AND MAINTENANCE This portion of the owner s 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 of all components 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 asteris
8. 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 amp unloading WARN The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Page 6 A 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 catche
9. lever mounting nut Rotate lever to be even with other side and tighten nut AUNT BOL LEV MOUNTING NUT ADJUST POSITION TO FORWARD RANGE OF CONTRO LEVER IF NECESSARY 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 38 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 BRAKEPLATE 1 Itis not necessary to remove the clutch from the motor i 554 s os 2 Locate the three holes in the brake plate one near each i NOS adjustment nut figure 1 Figure 1 3 Inserta 012 inch feeler gauge into one of the three PO windows Be careful to position the feeler gauge 207 26 2 gt ARMATURE between the rotor and armature faces figure 2 012 INC 4 NS FEELER GAUGE IEE REQUIRED 4 Ti
10. 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 Check to assure that the drive chains are properly adjusted A loose chain may come off causing loss of control Page 9 DIXON LIMITED WARRANTY POLICY HYDRO GEAR MODELS This warranty policy applies to all Commercial Hydrostatic mowers purchased onor 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 usedforresidential homeowner applications used only atowner 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 Warrantyapplies onlytooriginalretail purchaserofnewand unusedmowersandaccessories 2 AllDixon warranty mustbe accomplished by authorized Dixon dealersandin accordance with Dixon warranty policy andallowances Allwarrantyclaims mustbe approved by Dixon Industries Inc 3 Battery warranty Limited to 90 daysfromdate of purchase 4 Accessories Warranty GrassCatchers SnowBlades Tine Rakes Covers etc Limite
11. transmission The hydrostatic transmissions in turn power a fully enclosed HydroGear gearbox 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 Electric by key switch operation with safety interlocks on parking brake and blade drive clutch Front 11X 4 X5 ribbed tread Rear 20 X 10 X 8 Multi Trac Front 16 21 Ibs Rear 8 14 Ibs 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 Width 51 42 Deck 60 50 Deck 72 60 Deck Height 45 Length 72 Weight 615 Ibs 42 Deck 680 Ibs 50 Deck 685 Ibs 60 Deck Additional information provided in service instructions under the individual component SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE 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 lt 9 N A X ss 2 RM a ds i d d 2 a E d N EN is V 7 SLIDE En CS FEE EJ gt DI
12. 1999 Operator s Manual IMPORTANT READ CAREFULLY The Dixong ZTR amp 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 Dixone ZTR e 5000 Series Commercial Mowers Your Dixon dealer will gladly answer any questions See your dealer for warranty service parts and repairs DIXON INDUSTRIES INC BLOUNT International Inc Co PO BOX 1569 COFFEYVILLE KS 67337 0945 316 251 2000 5000 Series INDEX SAFE Pages 2 7 WARRANTY POLICY Page 8 9 SPECIFICATIONS sai aa Page 10 12 SEAT ADJUSTMENT 13 CONTROL Si aga sua Pages 14 17 OPERATION INSTRUCTIONS Pages 18 24 CARE AND Pages 25 40 STANDARD SERVICE PARTS LIST Page 41 42 TROUBLESHOOTING some 43 45 Part 8965 0798 SAFETY RIDING LAWNMOWERS IF IMPROPERLY OPERATED CAN CAUSE SERIOUS INJURY OR DEATH The most common causes of injury to the operator or bystander BLADECONTACT RUN OVER fead and u
13. Clean any spilled oil from engine and chassis 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 41 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 32 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 INSERT END OF LINK HERE 5283 LINK 3 Slide deck from beneath chassis 4 Reverse procedure to reinstall deck to chassis Page 33 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 Page 34 FRONT ADJUSTERS A Place the
14. DY SEAT MOWER DECK BLADE DRIVE DRIVE SYSTEM ENGINE STARTING SYSTEM TIRES RECOMMENDED TIREPRESSURE CAPACITIES DIMENSIONS NOTE SPECIFICATIONS Model ZTR 5020 11 GA rectangular tube 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 Designed for operator comfort by use of high density closed cell foam padded back rest and arm rests upholstered with Cordura water repellent fabric Seat is adjustable fore and aft 3 Decks are available 42 amp 60 are made of stamped steel 50 is made of 11 GA fabricated welded construction with external reinforcement ribs 3 blades combine for either a 42 50 or 60 cut width Cut height approximately 1 5 to 4 5 via 8 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 20HP Briggs amp Stratton Intek overhead valves replaceable oil filter full pressure lube system dual element air cleaner integral fuel pump Electric by key switch operation with safety interlocks on parking brake and blade drive clutch Front 11 X 4 X5 smooth profile Rear 20 X 10 5 X 8 Multi Trac Front 16 21 Ibs Rear 8 14 lbs Fuel 4 8 gall
15. POLICY ESTATE MODELS This warranty policy applies to all Estate Mowers purchased on or after September 1 1997 WARRANTY Commercial Applications Dixon Estate Models used in any commercial application are warranted for a period of six 6 months from date of purchase Commercial applications or use is defined as any use other than at owners primary place of residence Home Owner Applications Dixon Estate Models used primarily at the owner s place of residence are warranted for a period of two 2 years from date of purchase 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 AllDixon 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 Thefollowing items a
16. S 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 Ibs Page 31 CARE AND MAINTENANCE CAUTION HOT oil may cause burns Allowengineto 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 TOENGINE Ce To CS Push the valve body in and twist into the detent notch OIL FILL
17. TEMS 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 TEST a Place Parking Brake in ON position b Engage blade drive switch c Turn ignition switch to START Engine should not turn over or attempt to start SEAT SWITCH TEST a In a 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 Page 21 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 p WS 1 Key will return to Run position V 4S N US 4 Once engine starts to warm up slowly move CHOKE ROTILE 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 STARTINGINSTRUCTIONS X Engine has been operated 1 Move throttle control to 1 4 to 1 2 setting 2 Insert
18. USTE ss SS 15 CONTROLS CHOKE CONTROL THROT I CONTROL PARKING BRAKE V R BLADE CUP HOLDER N BREAKER Page 16 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 CAUTION Engage parking brake before starting engine TO SET PARKING BRAKE The hand operated parking brake is located at left hand side of 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 brake before moving mower HYDRO GEAR DRIVE SYSTEM Allows 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 Page 17 CONTROLS NEUTRAL SLOW FAST 90 SLOW FORWARD FORWARD DEN REVERSE left turn opposite From neutral position gently push both drive levers forward To increase speed move levers farther forward TO GO BACKWARD TURNING BRAKING From neutral position gently pull both drive levers toward you Turning is controlled by moving one drive lever slightly forward or rearward of the other To turn left move left leve
19. avily fertilized 4 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 J 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 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 across the marginal areas a second time 6 CUT HIGH MOW OFTEN Page 23 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 2 Set engine speed control to the wide open or full setting 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 If the grass is tall
20. dto 90 daysfromdateof purchase 5 Warrantydoes notapplytodamageintransitorincidentsof misuse negligence accidents oralteration Theuseof parts or components otherthanthose supplied by Dixon Industries Inc VOIDS ALL WARRANTY 6 Thefollowing items are notcovered bythis warranty policy Pickupanddeliverychargesfortransportation of mowertoandfroman Authorized Dixon Dealer s place of business Routinemaintenanceoradjustments Belts chains sprockets cutting blades JEngines Allenginesusedon Dixon ZTR mowers are warranted by each individual engine manufacturer e Anycosts orexpense of providing substitute equipmentwhile repairworkisbeing performed on awarranted mower a b c d T Thereisnootherexpresswarranty Implied warranties including those of merchantability andfitnessfora particular purpose arelimited tothesame duration ofthe express warranty andtotheextent permitted bylawany and allimplied warranties are excluded Liabilities forconsequentialdamages underany andallwarranties are excluded WARRANTY VALIDATION Atthe time ofsale selling dealer must review each portion of this warranty document complete theinformation section below secure customer ssignatureand send copy to Dixon Industries Inc Date of Purchase Model sin DM Owner s Name Dealership Address Address Dealer s Signature Owner s Signature SEE DEALER FOR DETAILS Page 10 DIXON LIMITED WARRANTY
21. e of grass or conditions being mowed LEFTREAR ADJUSTER DECKLEVELINGADJUSTMENT POINTS 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 ADJUSTMENTPOINTSFOR T BOXBELT TENSION 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 35 CARE AND MAINTENANCE PARKING BRAKE CABLE ADJUSTMENT Make necessary adjustments to the T Box to Hydrostat belt as shown on page 32 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
22. en to operate the mower e Use extra care when approaching blind corners shrubs trees or other objects that may obscure vision Page 8 SAFETY SERVICE e 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 e Never run a mower inside a closed area The exhaust fumes are toxic e Keep nuts and bolts tight especially blade attachment bolts and keep equipment in good condition e Never tamper with safety devices Check their proper operation regularly e Keep mower free of grass leaves or other debris buildup Clean up oil or fuel spillage Allow mower to cool before storing e Stop and inspect the equipment if you strike an object Repair if necessary before restarting e Never make adjustments or repairs with the engine running e 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 e Mower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing them e Batteries contain sulfuric acid To
23. ghten the adjusting nut adjacent to the window with the feeler gauge inserted until the gauge fits Figure 2 snugly between the rotor and armature The gap should not be so tight that the feeler gauge cannot be reinserted after removal 5 Repeat Steps 3 and 4 at the other two windows 6 Re check the air gap at each window and make minor adjustments as necessary to achieve a consistent 012 inch air gap 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 39 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 Use automotive engine oil filters These filters require
24. 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 ponor operate the engine in an enclosed area The exhaust fumes are toxic Page 22 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 Setthe 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 he
25. k require more frequent attention 1 Drive system belts and controls 2 Mower deck belts 3 Tire pressures 4 HydroGear oil tank 5 Tightness of all nuts and bolts 6 Battery fluid level 7 Engine oil Before each use or every 8 hours 8 Electric blade clutch air gap setting Before performing any maintenance shut off engine A CAUTION 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 27 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 4 When replacing blade tighten blade nut securely Refer to diagram Wear heavy thick gloves when holding onto mower blade avoid the CAUTION sharp edge of the blade NOTE Be sure blade is centered on pilot before tighteni
26. 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 Measure from the floor surface up to the bottom ofthe blade tip on the discharge side ofthe 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 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 Atthis 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 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 typ
27. nderstand this manual to prevent injuries Page 4 TIP OVER BACK OVER SAFETY 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 Dang AN DA NG E R indicates an M ren PR 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 NI ARNING Cauti A CA U T O N indicates a ee situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices Page 5 A SAFETY This cutting mower is capable of amputating hands amp 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
28. ng nut to 60 ft Ibs torque Page 28 CARE AND MAINTENANCE BELT TENSION ENGINE TO MOWER DECK BELT 42 and 50 P N6111 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 adjustmentto be made MOWER DECK SERPENTINE BELT 42 P N 6109 50 P N 1300 60 P N 6939 Refer to illustration for adjustment procedure DLER IDLER IDLE WELDMENT SHOCK _ ze UT TIGHTEN ORLOOSEN HEX NUT TO ACHIEVE THIS DIMENSION 50 amp 60 5 8 42 3 4 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 29 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 LOCATIONS SERVICE INTERVALS RECOMMENDED GREASE Page 30 ON OFF Number of grease zerks used 5 1 each front wheel caster tube 1 each mower deck hub Every 50 hours of operation 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 CARE AND MAINTENANCE REAR WHEEL
29. o 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 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 13 GA stamped steel construction 3 blades combine for a 42 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 17HP Briggs amp Stratton Intek overhead valves replaceable oil filter full pressure lube system dual element air cleaner impulse fuel pump Electric by key switch operation with safety interlocks on parking brake and blade drive clutch Front 11X 4 X5 smooth profile Rear 20 X 10 5 X 8 Multi Trac Front 16 21 Ibs Rear 8 14 lbs Fuel 4 8 gallons total dual tanks Hydrostat oil tank 3 quart with in line 10 micron filter Hydrostat oil recommendation refer to page 37 Engine 2 qts SAE 30 with filter Width 54 Height 45 Length 72 Weight 615 Ibs Additional information provided in service instructions under the individual component SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE CHASSIS BO
30. ons total dual tanks Hydrostat oil tank 3 quart with in line 10 micron filter Hydrostat oil recommendation refer to page 37 Engine 2 qts SAE 30 with filter Width 54 42 Deck 60 50 Deck 73 60 Deck Height 45 Length 72 Weight 630 Ibs 42 Deck 668 Ibs 50 Deck 685 Ibs 60 Deck Additional information provided in service instructions under the individual component SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE Page 13 CHASSIS BODY SEAT MOWER DECK BLADEDRIVE DRIVE SYSTEM ENGINE STARTING SYSTEM TIRES RECOMMENDED TIRE PRESSURE CAPACITIES DIMENSIONS NOTE Page 14 SPECIFICATIONS Model ZTR 5022 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 42 Deck 13 GA Stamped Steel Construction 42 Cut Width 50 Deck 11 GA Fabricated Construction Reinforcement Ribs 50 Cut Width 60 Deck 10 GA Stamped Steel Construction 60 Cut Width Cut height approximately 1 to 4 via 7 position lift handle Electric clutch Each rear wheel is independently driven by a HydroGear BDU 10L Series 70 hydrostatic
31. or engine oil changes and air filter maintenance Protect your engine investment use only original equipment filters Kohler 22HP Pre Cleaner Foam Element 45083 01 Cartridge Air Cleaner 45083 02 Engine Oil Filter 12050 01 Briggs amp Stratton 20HP Pre Cleaner Foam Element 273638 Cartridge Air Cleaner 499486 Engine Oil Filter 492932 Briggs amp Stratton 17 HP Pre Cleaner Foam Element 272403 Cartridge Air Cleaner 496894 Engine Oil Filter 492932 Page 44 MOWER CUT QUALITY TROUBLESHOOTING 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 ofthe 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 Poor cut quality CAUSES Ground speed REMEDY Reduce mowing speed Poor cut quality Incorrectengine to mower deck belt Refer to page 40 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 31 for deck leveling procedure Poor cut quality Grass buildu
32. oting guide Be sure that deflector is properly installed on the A CAUTION discharge chute 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 Best Cut Heights Zoysia 2 2 1 2 Blue Grass 1 1 2 3 Fescue Blends 1 1 2 3 St Augustine Mid South 1 1 2 2 St Augustine Deep South 3 4 Tifton Bermuda 1 1 2 Centipede 1 1 2 2 Common Bermuda 1 1 2 2 Bahia Argentina Pensacola 2 Page 25 OPERATION INSTRUCTIONS DECK ROLLERS 60 Deck Purpose The spring loaded deck rollers located at the front corners of the 60 mower deck
33. p under mower deck Clean out underside of mower deck Poor cut quality Improper blades Refer to page 40 for part numbers Poor cut quality Uneventire pressures Refer to page 39 for correct tire pressures Page 45 TROUBLESHOOTING DRIVE SYSTEM SITUATION CAUSES REMEDY Mower pulls to one Forward travel Refer to page 35 for procedure side or the other speed adjustment or consult your dealer for repair Drive system will not Incorrectoilfilterinstalled Replace with correct Dixon function on either side on system filter after changing hydrostatic transmission Hydrostatic Consult your dealer for repairs oil and filter transmissions are air Continued attempted operation locked low or no oil may result in damage to the return to tank system Drive system functions Loss of set screw tension Consult your dealer for repairs on one side only on hydrostatic transmission pulley Loss of power and speed Incorrect parking brake Refer to adjustment procedure on both hydrostatic cable adjustment page 33 or consult your dealer transmissions for repair Incorrect or worn drive Replace with correct belt belt Mower creeps in Neutral adjustment Refer to adjustment procedure page neutral position 34 or consult your dealer for repair Page 46 ELECTRICAL SYSTEM SITUATION Starter will not turn engine over TROUBLESHOOTING CAUSES Circuit breaker disengaged REMEDY Push button to re
34. r 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 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 Page 18 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 CONTROLS BLADE DRIVE IN Located on control panel on operator s right lt DIXON To engage blades Pull up on the switch JAN A ZTR 4 To disengage blades Push 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 breakertrips push button to reset If this condition 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
35. re not covered by this warranty policy a Pickup 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 HydroGear Filters d Engines All engines used on Dixon ZTR mowers are warranted by each individual engine manufacturer e Anycosts orexpense of providing substitute equipment while repair work is being performed on a warranted mower 7 Thereisnoother express warranty Implied warranties including those of merchantability and fitness for a particular purpose are limited to the same duration ofthe express warranty andto 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 Atthe 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 S N Owner s Name Dealership Address Address Owner s Signature Dealer s Signature SEE DEALER FOR DETAILS Page 11 CHASSIS BODY SEAT MOWER DECK BLADE DRIVE DRIVE SYSTEM ENGINE STARTING SYSTEM TIRES RECOMMENDED TIREPRESSURE CAPACITIES DIMENSIONS NOTE Page 12 SPECIFICATIONS Model ZTR 5017 11 GA rectangular tube Tw
36. rs 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 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 7 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 alert and turn mower off if a child enters the area Before and during backing look behind and DOWN for small children e Never carry children They may fall off and be seriously injured or interfere with safe mower operation Never allow childr
37. set 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 likelythan component failure Page 47 NOTES DIXON INDUSTRIES INC ABLOUNT International Inc Co DIXO Eo ernational Inc COFFEYVILLE KS 67337 0945 316 251 2000 FAX 316 251 4117 OWNER BLOUNT INFORMATION DATE PURCHASED MOWER MODEL NUMBER PURCHASED FROM Name Address MOWER SERIAL NUMBER DM DATE OIL CHANGED DATE ENGINE TUNED ZTR Mowers WARN The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Dixone and ZTRe are registered trademarks of Dixon Industries Inc DIXON INDUSTRIES INC A BLOUNT International
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