Dixon ZTR 5000 Series, Operator'S Manual

Page 1: ......

Page 2: ...ator s manual carefully and become completely familiar with the controls The information in this operator s manual applies to all Dixon ZTR 5000 Series Model Mowers Your Dixon dealer will gladly provide a check out ride and answer any questions See your dealer for warranty service parts and repairs DIXON INDUSTRIES INC A BLOUNT COMPANY AIRPORT INDUSTRIAL PARK PO BOX 1569 COFFEYVILLE KS 67337 O945 ...

Page 3: ...ICATIONS Page 7 9 4 SEAT ADJUSTMENT Page 10 5 CONTROLS Pages 11 14 6 OPERATION INSTRUCTIONS Pages 15 19 7 CARE AND MAINTENANCE Pages 20 41 8 STANDARD SERVICE PARTS LIST Page 42 43 9 TROUBLESHOOTING Pages 44 46 10 DIAGRAMS Pages 47 65 Part No 8965 November 1994 ...

Page 4: ...bol BE ALERT to the potential for injury Follow recommended safety precautions and safe operating practices Danger indicates an imminently hazardous situation which if not avoided will result in death or serious injury Warning indicates a potentially hazardous situation which if not avoided could result in death or serious injury Caution indicates a potentially hazardous situation which if not avo...

Page 5: ...carry passengers Do not mow in reverse unless absolutely necessary Always look down and behind before and while backing Be aware of the mower discharge direction and do not point it at anyone Do not operate the mower without either the entire grass catcher or the deflector in place Slow down before turning Never leave a running mower unattended Always turn off blades set parking brake stop engine ...

Page 6: ... or other attachments These can change the stability of the mower Keep all movement on the slopes slow and gradual Do not make sudden changes in speed or direction Avoid starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly down the slope DO NOT Do not turn on slopes unless necessary and then turn slowly and gradually downhill if possible Do not mow near dr...

Page 7: ...ldren 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 sh...

Page 8: ...r other debris buildup Clean up oil or fuel spillage Allow mower to cool before storing Stop and inspect the equipment if you strike an object Repair if necessary before restarting Never make adjustments or repairs with the engine running Grass catcher components are subject to wear damage and deterioration which could expose moving parts or allow objects to be thrown Frequently check components a...

Page 9: ...oes not apply to damage in transit or incidents of misuse negligence accidents or alteration The use of parts or components other than those supplied by Dixon Industries Inc VOIDS ALL WARRANTY 6 The following items are not covered by this warranty policy a Pick up and delivery charges for transportation of mower to and from an Authorized Dixon Dealer s place of business b Routine maintenance or ad...

Page 10: ...The hydrostatic transmissions in turn power a fully enclosed Hydro Gear gearbox ENGINE 16 HP Kohler Magnum Vertical Crankshaft 4 Cycle Air Cooled Gasoline Twin Cylinder Opposed Aluminum Crankcase Removable Cast Iron Cylinder Barrels Electronic Ignition Full Pressure Lubrication STARTING SYSTEM Electric by key switch operation with safety interlocks on parking brake and blade drive clutch TIRES Fro...

Page 11: ...ission The hydrostatic transmissions in turn power a fully enclosed Hydro Gear gearbox ENGINE 20 HP Kohler Magnum Vertical Crankshaft 4 Cycle Air Cooled Gasoline Twin Cylinder Opposed Aluminum Crankcase Removable Cast Iron Cylinder Barrels Electronic Ignition Full Pressure Lubrication STARTING SYSTEM Electric by key switch operation with safety interlocks on parking brake and blade drive clutch TI...

Page 12: ...atic transmission The hydrostatic transmissions in turn power a fully enclosed Hydro Gear gearbox ENGINE 22 HP Kohler Command 4 Cycle Twin Cylinder V Configuration Overhead Valve Air Cooled Gasoline Vertical Shaft Aluminum Head and Crankcase with Cast Iron Liners Oil Cooler STARTING SYSTEM Electric by key switch operation with safety interlocks on parking brake and blade drive clutch TIRES Front 1...

Page 13: ...upper body rearward 3 Loosen two front seat adjustment knobs P N 3978 and slide seat forward or backward to desired position 4 Re tighten front seat adjustment knobs P N 3978 DO NOT operate mower without seat adjustments properly tightened 5 Carefully lower upper body and seat assembly to the closed position MODELS ZTR 5501 ZTR 5601 MODEL ZTR 5421 Page 10 ...

Page 14: ...CONTROLS ...

Page 15: ...ing brake is located at left hand side of mower To engage brake pull lever up and to the rear To release brake move lever forward and down NOTE Always set parking brake before dismounting Release parking brake before moving mower HYDRO GEAR DRIVE SYSTEM Allows the mower to turn on its own axis zero turning radius Drive levers control braking turning travel speed and direction Each lever controls o...

Page 16: ...irection to neutral To turn on mower s own axis zero turning radius stop and move one lever to reverse position and the other to forward position BRAKING To brake mower move both levers in direction opposite of travel release levers to neutral set parking brake Park only on level surfaces TWIN FUNCTION THROTTLE CONTROL LEVER Located on control panel to operators right Throttle control for engine s...

Page 17: ... electrical system is by 1 15 amp circuit breaker If circuit breaker trips 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 Model ZTR 5421 Eight positions of adjustment Model ZTR 5501 Model ZTR 5601 Move lever in and forward to...

Page 18: ...l 5 Check gas caps to be sure they are in place 6 Be sure parking brake is on 7 Mower blade drive is off 8 Know how to stop engine Turn key to off position 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 O...

Page 19: ...01 may require partial choke setting to start even if the engine has been operated for a period of time 4 Engine must be operated at wide open or maximum setting to insure adequate lubrication cooling and cut quality of the mower deck DO NOT operate the engine in an enclosed area due to the harmful exhaust gas produced NOTE On initial operation set throttle at slow speed Engine cannot be restarted...

Page 20: ...ecially 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 A Sharp Blade Throughout The Cutting Season This is very important Optimal mulching performance cannot be obtained with a dull or nicked blade 6 Keep The Underside Of The Mower Deck Clean Remove all grass and dirt b...

Page 21: ... 5 Use only the 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 6 Maintain Sharp Blade s Throughout The Cutting Season 7 Operate the mower at a slower ground speed than when mowing without a grass catching attachment Watch for low hanging branches or other obstacles which might hit the catcher top whi...

Page 22: ...eep The Underside Of The Mower 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 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 loc...

Page 23: ...nt attention 1 Drive system belts and controls 2 Mower deck belts 3 Tire pressures 4 Hydro Gear 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 allow to cool ENGINE For engine operating and maintenance information refer to the engine operating and...

Page 24: ...oper blade position prior to removal 1 Safely raise front of mower 2 Hold or block blade from turning CAUTION Wear heavy thick gloves when holding onto cutter blade avoid the sharp edge of the blade NOTE Be sure blade is centered on pilot before tightening bolt to 60 ft Ibs torque ...

Page 25: ...h push the deck assembly forward and do not require any additional adjustment to be made MOWER DECK SERPENTINE BELT Model ZTR 5421 Model ZTR 5501 Model ZTR 5601 Refer to illustration for adjustment procedure Belt deflection or movement should be approximately 1 4 when measured at mid point between pulleys Periodically inspect both belt and idler systems P N 6111 P N 6939 P N 6109 P N 1300 P N 6938...

Page 26: ...LS RECOMMENDED GREASE Number of grease zerks used 7 1 each front wheel caster and each front wheel hub 1 each mower deck shaft Every 50 hours of operation Name brand wheel bearing or multi purpose grease Rotate or spin each front wheel after 3 full pumps of the grease gun Repeat until the appearance of grease is noted around each caster Lubrication of the m ower deck shafts will help dispel moistu...

Page 27: ...ch 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 asterick 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 stem...

Page 28: ...equency of oil changes 1 Push the valve body in and twist into the detent notch 2 Clean any spilled oil from engine and chassis 3 Refill engine with type and quantity of oil recommended by the engine manufacturer in engine literature NOTE Engine oil changes on the 5000 Series Models will require replacement of the oil filter These filters can be obtained from any authorized Kohler engine dealer PR...

Page 29: ...hassis 2 Install rear hanger rods on lift frame Slide lift plate on hanger rods small holes in lift plate will face rear of mower and start nylok nuts on each hanger rod until approximately 1 2 inch of threads are exposed 3 Position mower deck under chassis 4 Raise front of mower deck and slide front support rod through lift frame and tabs on mower deck Install hair pin clips on front and rear of ...

Page 30: ...ide check that measurement is the same If adjustment is required turn the nut on the bottom of the front threaded adjuster up or down until both side to side measurements are equal Retain measurement D Rotate or turn both outer blades to align with the deck in front to rear manner Move to the left rear threaded adjuster left rear is designated from operat or position on the mower Turn adjuster nut...

Page 31: ...will result in rapid belt stretch with subsequent loss of adjustment potential ADJUSTMENT PROCEDURE TRIPLE PULLEY TO HYDROSTATIC TRANSMISSIONS 1 Remove front lower body from mower chassis to gain easy access to triple pulley adjustment bolts Open upper body fully 2 If belts are in good condition evenly tighten adjustment bolts until each hydrostatic transmission belt has approximately 1 16th of an...

Page 32: ...be routed inside of welded tab on engine mount Incorrect routing will result in a loss of clutching action when parking brake is engaged NOTE L rod P N 1685 acts as a belt guide and does not require a nut on the threaded end which passes through the welded tab on the chassis 2 Engage parking brake Start engine Move throttle control to 1 2 3 4 maximum engine speed setting ...

Page 33: ... C Belt alignment is controlled by moving pulley P N 1751 in or out This pulley is mounted on a spring steel plate 4 ADJUSTMENT PROCEDURE IF REQUIRED Engage parking brake Stop engine If belt running path is either centered on the pulley or slightly to the right side of the pulley no adjustment should be needed If adjustment is required loosen nut P N 3206 on J bolt P N 3918 to move pulley to the r...

Page 34: ...lt drive should be held to approximately 1 3 4 A To adjust this distance loosen the nuts on both ends of the rod extending between the idler plate and the brake shaft B Turn the rod as required to achieve desired pulley travel of approximately 1 3 4 when the brake handle is released C Tighten nuts firmly against the ball joint rod ends ...

Page 35: ... times to determine whether each brake band is functioning correctly The brake bands should fit tightly around brake drums with the brake handle on or pulled upward If band is too loose tighten the nut on the threaded end of eyebolt extending from brake band If band does not fully release drum loosen nut until achieving desired results Repeat procedure if necessary Page 32 ...

Page 36: ... 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 stop blocks If adjustment is required loosen the lock nuts on the lever stop and turn the bolt in until the lever hits the stop block before resistance is felt in the hydrostat Page 33 ...

Page 37: ...ngine and disengage parking brake Caution should be used when releasing parking brake as mower may tend to creep or move prior to adjustment If adjustment is required loosen lock nuts at each end of the control rods and back off the tension on each spring block Turn control rods in or out until neutral is obtained on each hydrostat Re tighten lock nuts and tension bolts on spring blocks ...

Page 38: ... 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 Page 35 ...

Page 39: ...ing fully and apply tension to the belt At this time check that the cable which pulls the idler to a neutral position has approximately 1 1 2 to 2 inches of free play If adjustment is required loosen the lock nuts on the cable block and turn cable sleeve in or out to achieve desired measurement Re tighten lock nuts NOTE Cable must have the above dimension with parking brake released or drive belt ...

Page 40: ...ngine and disengage parking brake Caution should be used when releasing parking brake as mower may tend to creep or move prior to adjustment If adjustment is required loosen lock nuts at each end of the control rods and back off the tension on each spring block Turn control rods in or out until neutral is obtained on each hydrostat Re tighten lock nuts and tension bolts on spring blocks Page 37 ...

Page 41: ...If adjustment is required loosen the lock nuts on the lever stop and turn the bolt in until the lever hits the stop block before resistance is felt in the hydrostat NOTE Balance of travel speed If mower tends to pull to either side re adjust lever stop on fast side to slow the hydrostat down and even out the ground speed DO NOT SPEED UP THE SLOW SIDE AS OVER STROKING OF THE HYDROSTAT COULD RESULT ...

Page 42: ...f the three windows Be careful to position the feeler gauge between the rotor and armature faces figure 3 f figure 1 6 Tighten the adjusting nut adjacent to the window with the feeler gauge inserted until the gauge fits snugly between the rotor and armature The gap should not be so tight that the feeler gauge cannot be reinserted after removal 7 Repeat Steps 5 and 6 at the other two windows 8 Re c...

Page 43: ...20 W 50 Cold climate usage 10 W 30 Another alternative that will provide excellent all climate performance and extended time between oil changes is a 15 W 50 synthetic engine oil P N 5565 IMPORTANT The oil filter is a special 10 micron design for use on vacuum or suction oil flow systems Use automotive engine oil filters These filters require a pressure to allow oil flow Usage will result in an ai...

Page 44: ... is located on frame at rear of engine it will begin with DM Refer to Warranty Registration Form P N 8289 See your Dixon dealer for replacement parts warranty or service PLEASE HELP PROTECT THE ENVIRONMENT BY AVOIDING ALL CHEMICALS WHICH MAY DAMAGE OR CAUSE HARM TO PLANTS AND ANIMALS IN YOUR AREA Page 41 Correct tire pressure is important for correct operation of mower Wash mower periodically Clea...

Page 45: ... MODEL ZTR 5501 Standard P N 8689 Hi Lift P N 9265 Engine To Mower Deck P N 6111 Serpentine Belt P N 1300 Engine To T Box P N 1714 T Box To Hydros P N 1765 Grass Blower Belt P N 4934 MODEL ZTR 5601 BLADES BELTS Hi Lift P N 9383 Engine To Mower Deck P N 6938 Serpentine Belt P N 6939 Engine To T Box P N 1714 T Box To Hydros P N 1765 MODELS ZTR 5421 ZTR 5501 ZTR 5601 Hydrostatic Transmission Filter B...

Page 46: ...ne Oil Filter 52050 02 Pre Cleaner Foam Element 45083 01 Cartridge Air Cleaner 52082 04 Engine Oil Filter 12050 01 IMPORTANT Some applications extreme dirt conditions or the use of a grass catcher may require that the engines used on the 5000 Series Models be fitted with an OPTIONAL Kohler fresh air filter system Listed below are the Kohler kit numbers required to adapt these components to the var...

Page 47: ...also available to provide assistance to you Poor cut quality Un level mower deck Consult your dealer Poor cut quality Uneven tire pressures Check and adjust as required per operators manual SITUATION CAUSES REMEDY Poor cut quality Ground speed Reduce mowing speed Poor cut quality Incorrect engine to mower deck belt Refer to page 42 for part numbers Poor cut quality Engine RPM too low Increase engi...

Page 48: ...il and filter Incorrect oil filter installed on system Hydrostatic transmissions are air locked low or no oil return to tank Replace with correct Dixon P N 5565 filter Consult your dealer for repairs Continued attempted operation may result in damage to the system Drive system functions on one side only Loss of set screw tension on hydrostatic transmission pulley Consult your dealer for repairs Lo...

Page 49: ...nctioning 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 ar...

Page 50: ...5421 Drive Pulley Hydro Gearbox ...

Page 51: ...5501 T Box Hydro Gearbox ...

Page 52: ...5601 T Box Hydro Gearbox ...

Page 53: ...5000 Series Gearbox ...

Page 54: ...5421 Mower Deck ...

Page 55: ...5501 Mower Deck ...

Page 56: ...5601 Mower Deck ...

Page 57: ...5421 Chassis ...

Page 58: ...5501 Chassis ...

Page 59: ...5601 Chassis ...

Page 60: ...5421 Fuel Hydro Tanks Fittings ...

Page 61: ...5501 Fuel Hydro Tanks Fittings ...

Page 62: ...5601 Fuel Hydro Tanks Fittings ...

Page 63: ...5421 Body ...

Page 64: ...5501 Body ...

Page 65: ...5601 Body ...

Page 66: ...5421 Wiring ...

Page 67: ...5501 Wiring ...

Page 68: ...5601 Wiring ...

Page 69: ...OUNT COMPANY AIRPORT INDUSTRIAL PARK PO BOX 1569 COFFEYVILLE KS 67337 O945 316 251 2OOO FAX 316 251 4117 OWNER INFORMATION DATE PURCHASED MOWER MODEL NUMBER PURCHASED FROM MOWER SERIAL NUMBER DATE OIL CHANGED DATE ENGINE TUNED ...

Page 70: ......