Dixon ZTR 5017Twin manual

1 Page 5000 SERIES ZTR ® MOWERS Operator's Manual 2001[...]

Page 2 IMPOR T ANT - READ CAREFULL Y The Dixon ZTR M o wer is both easy and fun to operate. H ow ever , any power mow er must be operated properly to be safe. It is not a to y or a recr eational vehicle. Befor e you start to use the mower , read the operator's manual car efully and become completely familiar with the controls. The information [...]

3 Page INDEX SAFETY .................................................................. P ages 4- 9 W ARRANT Y POLICY ............................................ P age 10 SPECIFICA TIONS ................................................. P age 11-13 SEA T ADJUSTMENT ............................................ P age 14 CONTR OLS ....................[...]

Page 4 ...read and understand this manual to prevent injuries. TIP-OVER BACK-OVER RUN-OVER BLADE CONTACT SAFET Y RIDING L A WNMO WERS, IF IMPROPERL Y OPERA TED, CAN CA USE SERIOUS INJUR Y OR DEA TH The most common causes of injur y to the operator or bystander ...[...]

5 Page SAFET Y SAFETY SYM BOLS Safety Alert Symbol When you see this symbol, BE ALER T to the potential for injury . F ollow r ecommended safety pr ecautions and safe operating practices. Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. W ar ning indicates a potentially hazardous situ[...]

Page 6 GENERAL OPERA TION: • 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[...]

7 Page SAFET Y SL OPE OP ERA TION: Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in sev ere injur y 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 s[...]

Page 8 SAFET Y CHILDREN: T ragic 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 responsi[...]

9 Page SAFET Y SER VICE: • 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[...]

Page 10 DIXON INDUSTRIES, INC. a BLOUNT company AIRPORT INDUSTRIAL PARK PO BOX 1569 COFFEYVILLE KS 67337 0945 316 251 2000 FAX 316 251 4117 DIXON LIMITED WARRANTY POLICY - COMMERCIAL MODELS Models 6000 & 7000 WARRANTY: Home Owner Application: This Dixon Warranty term is for a period of two (2) years from date of purchase. Commercial Application[...]

11 Page SP ECIFICA TIONS M odel ZTR 5020 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 operator comfort by use of high density c[...]

Page 12 CHASSIS: 11 GA - rectangular tube BODY: 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. SEAT: Designed for operator comfort by use of high density closed cell foam padded back and arm re[...]

13 Page SP ECIFICA TIONS M odel ZTR 5017T win 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 operator comfort by use of high dens[...]

Page 14 SEA T ADJUSTMENT INSTR UCTIONS 5000 Series 1. G rasp seat slide adjuster and move it into adjustment position. 2. S lide seat for ward or backwar d. 3. Release seat slide adjuster . Seat Slide Adjuster[...]

15 Page CONTR OLS[...]

Page 16 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. . T O SET P ARKING 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). NO TE : Always set pa[...]

17 Page CONTR OLS T O GO FOR W ARD: From neutral position, gently push both drive levers forward. To increase speed, move levers farther forward. T O GO BACKW ARD: 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 other. To turn left, move le[...]

Page 18 CONTR OLS BLADE DRIVE: Located on control panel, on operator's right. To engage blades: Pull up on the switch. To disengage blades: Push down. CIR CUIT BREAKER: Located on control panel, on operator's right. Protection of the electrical system is by (1) 15 amp circuit breaker. If circuit breaker trips, push button to reset. If thi[...]

19 Page OP ERA TION INSTR UCTIONS Safe and successful operation will depend upon the operator having the correct knowledge of all controls used on the mower and making good judgements about the terrain to be mowed. NEVER allow anyone to operate the mower without complete knowledge of all controls and their functions. During initial operation, "[...]

Page 20 P ARKING BRAKE SWIT CH TEST : a) Place P arking Brake in OFF position b) T ur n ignition switch to ST AR T E NGINE SHOULD NO T TURN O VER OR A TTEMPT TO ST AR T ! BLADE DRIVE SWIT CH TEST : a) Place P arking B rake in ON position b) Engage blade drive switch c) T urn ignition switch to ST AR T E NGINE SHOULD NO T TURN O VER OR A TTEMPT TO S[...]

21 Page OP ERA TION INSTR UCTIONS ST AR TING INSTR UCTIONS: 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. Key will return to "Run" position. 4. Once engine starts to warm up , [...]

Page 22 OP ERA TION INSTR UCTIONS MO WING WITH A MUL CHING A T T A CHMENT : 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 t[...]

23 Page OP ERA TION INSTR UCTIONS MO WING WITH A GRASS CA T CHER A TT A CHMENT : 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 Wet. Wet grass will clog both the[...]

Page 24 OP ERA TION INSTR UCTIONS CAUTION 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 [...]

25 Page OP ERA TION INSTR UCTIONS DECK ROLLERS : 60" Deck Purpose: The spring loaded deck rollers located at the front corners of the 60" mower deck are designed as an aid to limit turf scalping when mowing on uneven ground. Height: Normal height settings as installed at the factory allows each roller to ride slightly above the turf. This[...]

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[...]

27 Page CARE AND MAINTENANCE MO WER BL ADE 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. CA UTION Wear heavy, thick gloves when holding onto mower bla[...]

Page 28 REAR HANGER PIN BEL T TENSION ENGINE T O MO WER DECK BEL T : 42" and 50" P/N 6111 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 adjustment to be made. MO WER DECK SERPENTINE BEL T : 42" P/N 6109 [...]

29 Page CARE AND MAINTENANCE FUEL SHUT OFF V AL VE: 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. L UBRICA TION CHASSIS: Number of grease zerks used: (5) L OCA TIONS: (1) each front wheel caster tube (1) each mower deck hub SER VIC[...]

Page 30 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 accidents, which can result in [...]

31 Page CARE AND MAINTENANCE HOT oil may cause burns. Allow engine to cool before draining oil. CHANGING THE ENGINE OIL: 1. The "Dapco" oil drain valve is located on the left side of the engine crankcase. 2. Place a suitable container under the drain valve. The short piece of hose will help direct the oil. 3. To drain turn hex head valve [...]

Page 32 CARE AND MAINTENANCE MO WER DECK REMO V AL : 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 position. Belt can now be removed from mower deck pulley. 3. Slide deck from beneath chassis. 4. Reverse procedure to reinstall deck[...]

33 Page MO WER 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. A. Place the mower [...]

Page 34 CARE AND MAINTENANCE Adjustment of the drive system is limited to the actual function of the hydrostatic transmissions as outlined below. T -BO X T O HYDROST A T BEL T 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[...]

35 Page CARE AND MAINTENANCE NOTE: Cable must have the recommended 1-1/2 to 2 inches of free play with parking brake released or drive belt may slip, causing loss of power. P ARKING BRAKE CABLE ADJUSTMENT : Make necessary adjustments to the T-Box to Hydrostat belt, as shown on page 34. Position parking brake lever in the off or disengaged position.[...]

Page 36 CARE AND MAINTENANCE NEUTRAL ADJUSTMENT : CONTROL TUBE BOLT LOOSEN IN STEP A TIGHTEN IN STEP E JAM NUTS LOOSEN IN STEP B TIGHTEN IN STEP D 9067 CONTROL ROD ADJUST IN STEP C 5540 CONTROL TUBE 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 remov[...]

37 Page CARE AND MAINTENANCE FOR W ARD TRA VEL 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 [...]

Page 38 CARE AND MAINTENANCE PROCEDURE FOR ELECTRIC CL UT CH 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 b[...]

39 Page CARE AND MAINTENANCE HYDROST A TIC TRANSMISSION OIL AND FIL TER SER VICE 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 classification of SG/CD is recommended. RECOMMENDED OIL WEIGHT: Normal operation temperatures - 20 W 50 Cold[...]

Page 40 CARE AND MAINTENANCE HYDROST A TIC TRANSMISSION OIL & FIL TER SERVICE If transmission is to be serviced, proper air purging procedures must be followed, or damage will occur. Proceed as follows: 1. Remove oil filter from chassis, allowing oil to drain into container. Clean impurities from inside of reservoir, if necessary. 2. Install ne[...]

41 Page CARE AND MAINTENANCE WHEELS AND TIRES: Correct tire pressure is important for correct operation of mower. Front Tires 11 x 4 x 5 16-21 lbs. Rear Tires(5020&5023) 20 x 10.5 x 8 8-14 lbs. Rear Tire (5425) 18 x 9.5 x 8 8-14 lbs. NOTE: Check lug nuts periodically for tightness. ELECTRICAL SYSTEMS: Keep all connections clean and tight. CLEAN[...]

Page 42 ST ANDARD SER VICE P AR T S LIST 42" DECK BLADES: Lo Lift P/N 6236 S tandard Hi-Lift P/N 8688 BEL TS: Engine to M ower Deck P/N 6111 Serpentine Belt P/N 6109 Engine to T -Box P/N 7253 T -Box to Hy dros P/N 1765 G rass Blower B elt P/N 4983 50" DECK BLADES: Lo-Lift P/ N 94 43 S tandard Hi-Lift P/N 9444 BEL TS: Engine to M ower Deck[...]

43 Page ST ANDARD SER VICE P AR T S LIST K OHLER AND BRIGGS & STRA T T ON AIR AND OIL FIL TER P AR T 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. Kohler 5023 Air Fil[...]

Page 44 SITUATION CAUSES REMEDY Poor cut quality Ground speed Reduce mowing speed. Poor cut quality Incorrect engine to Refer to page 42 for part numbers. mower deck belt 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 [...]

45 Page SITUATION CAUSES REMEDY Mower pulls to one Forward travel Refer to page 37 for procedure side or the other speed adjustment or consult your dealer for repair. TR OUBLESHOO TING DRIVE SYSTEM: Incorrect oil filter installed on system. Hydrostatic transmissions are "air locked", low or no oil return to tank. Loss of set screw tension[...]

Page 46 ELECTRICAL SYSTEM: SITUATION CAUSES REMEDY Starter will not Circuit breaker Push button to reset turn en gine over disengaged Consult your dealer for repair Starter will not Dead battery Charge battery turn engine over Battery discharge Poor connections on Tighten or replace as required battery Battery water low Wrong battery installed in m[...]

47 Page DIXON INDUSTRIES, INC. A BLOUNT International Inc. Co. PO BOX 1569 COFFEYVILLE KS 67337 0945 316 251 2000 FAX 316 251 4117 Address DATE PURCHASED MOWER MODEL NUMBER Name DATE OIL CHANGED: DATE ENGINE TUNED: MOWER SERIAL NUMBER PURCHASED FROM O WNER INFORMA TION[...]

Page 48 Dixon ® and ZTR ® are registered trademarks of Dixon Industries, Inc. 5000Series 5020,5023&5425 Part No. 13089-0600 DIXON INDUSTRIES, INC. A BLOUNT INTERNATIONAL INC. CO. PO BOX 1569 COFFEYVILLE KS 67337 0945 316 251 2000 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth de[...]