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 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.
INDEX 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. SAFETY.................................................................Pages WARRANTY POLICY...............................................Page SPECIFICATIONS..................................................... Page SEAT ADJUSTMENT ...............................................Page CONTROLS...............................................................Pages OPERATION INSTRUCTIONS.................................Pages CARE AND MAINTENANCE..............................
SAFETY RIDING LAWNMOWERS, IF IMPROPERLY OPERATED, CAN CAUSE SERIOUS INJURY OR DEATH The most common causes of injury to the operator or bystander... BLADE CONTACT TIP-OVER RUN-OVER To avoid these and other accidents, read and understand the operator's manual. 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.
SAFETY 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 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 u p and thrown by the blade.
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.
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. • 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.
SAFETY SERVICE: • 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. • Never run a mower inside a closed are*.
DIXON LIMITED WARRANTY POLICY -- HYDRO-GEAR MODELS This warranty policy applies to all Hydro-Gear 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 used for residential homeowner applications (used only at owner's primary place of residence) are warranted for two (2) years from date of purchase or 400 hours of use, whichever occurs first.
SPECIFICATIONS Model ZTR 5421 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 closed cell foam padded back and arm rests. Seat is adjustable fore and aft.
SPECIFICATIONS Model ZTR 5501 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: Economically designed for operator comfort by use of high density closed cell foam, contoured back rest and arm rests. Seat is adjustable fore and aft.
SPECIFICATIONS Model ZTR 5601 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: Economically designed for operator comfort by use of high density closed cell foam, contoured back rest and arm rests. Seat is adjustable fore and aft.
SEAT ADJUSTMENT INSTRUCTIONS Models ZTR 5421 - ZTR 5501 - 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. Re -tighten front seat adjustment knobs, P/N 3 978. DO NOT operate mower without seat adjustments properly tightened. 5. Carefully lower upper body and seat assembly to the closed position.
CONTROLS
CONTROLS PARKING BRAKE: The parking brake used on the 5000 Series Models is designed to hold the mower from moving and is noHntended for use in stopping the mower while it is in motion. CAUTION Engage parking brake before starting engine. Do not leave engine running fo r extended periods of time without the parking brake engaged. Damage to the drive system could result. TO SET PARKING BRAKE: The hand operated parking brake is located at left hand side of mower.
CONTROLS: 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 b oth drive levers toward you. TURNING: Turning is controlled by moving one drive lever slightly forward or rearward of the other. To turn left, move left lever rearward of the right lever. To turn "square corners" move lever of desired direction to neutral.
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. Protection of the 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.
OPERATION INSTRUCTIONS The safe and successful operation of the 5000 Series Models will depend upon the operator h aving 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 functions. their Sound judgement by the owner will prevent accidents. BEFORE OPERATING MOWER: 1. Read engine manufacturer's operating and maintenance instructions. 2.
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 lever to wide open or maximum setting for actual operation of the mower deck. NOTE: Model ZTR 5601 may require partial choke setting to start even if the engine has been operated for a period of time. 4.
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. Set the engine speed control to the wide open or full setting. 2.
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 Wet. Wet grass will clog both the underside of the deck and the attachment chutes. Empty bags often to prevent plugging. 3.
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 44. CAUTION Be sure that detector is properly installed on the discharge chute 1. Set engine speed control to the wide open or full setting. 2. Do Not Attempt To Cu t Grass When It Is Wet.
CARE AND MAINTENANCE - 5000 SERIES MODELS This portion of the 5000 Series Models 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.
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. 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.
CARE AND MAINTENANCE - 5000 SERIES MODELS BELT TENSION ENGINE TO MOWER DECK BELT: Models ZTR 5421 & ZTR 5501 P/N 6111 Model ZTR 5601 P/N 6939 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. MOWER DECK SERPENTINE BELT: Model ZTR 5421 P/N 6109 Model ZTR 5501 P/N 1300 Model ZTR 5601 P/N 6938 Refer to illustration for adjustment procedure.
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.
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 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.
CARE AND MAINTENANCE - 5000 SERIES MODELS HOT oil may cause burns. Allow engine to cool before draining oil. CAUTION 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 u nder the drain valve. The fitting of a short piece of hose to the valve 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.
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 a cotter pin and washer. REMOVE AND DISCARD cotter pin and washer after engine to mower drive belt has been installed. 1. Loosen and remove front body mounting bolts (P/N 3368) and washers (P/N 3066).
CARE AND MAINTENANCE - 5000 SERIES MODELS MOWER DECK LEVELING PROCEDURE: There are a total of (4) threaded adjusters which will control the atti tude 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 on a smooth level surface, check tire pressures to insure the mower has a correct stance.
CARE AND MAINTENANCE MODEL ZTR 5421 DRIVE SYSTEM ADJUSTMENTS Successful adjustment of the Model ZTR 5421 "twisted" drive belt depends on a number of factors which must be observed. • If the "twisted" drive belt P/N 1860 has broken or is of a high hour use nature, replacement of belts, P/N 1859, that drive each hydrostatic transmission will be required due to belt stretch and wear. • The use of other than original belts will result in rapid belt stretch with subsequent loss of adjustment potential.
CARE AND MAINTENANCE MODEL ZTR 5421 DRIVE SYSTEM ADJUSTMENTS TWISTED BELT ADJUSTMENT: 1. Check routing of belt P/N 1860 from engine to triple drive pulley P/N 1850. Belt must 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.
CARE AND MAINTENANCE MODEL ZTR 5421 DRIVE SYSTEM ADJUSTMENTS TWISTED BELT ADJUSTMENT: 3. VISUAL BELT ALIGNMENT CHECK: A. .Stand on left side of mower. Disengage parking brake and observe engagement action of pulley P/N 1751 against drive belt P/N 1860. B. Correct drive belt position is either "c entered" on pulley or running "slightly to the right side" of the pulley (as viewed while standing on the left side of the mower facing forward.) NOTE: Belt must not run to left side of pulley. C.
CARE AND MAINTENANCE MODEL ZTR 5421 DRIVE SYSTEM ADJUSTMENTS TWISTED BELT ADJUSTMENT: 5. The idler pulley travel required to engage the belt 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.
CARE AND MAINTENANCE MODEL ZTR 5421 DRIVE SYSTEM ADJUSTMENTS BRAKE BAND ADJUSTMENTS: Located on each gearbox. Brake handle should be placed in both "off" and "on" positions several 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.
CARE AND MAINTENANCE MODEL ZTR 5421 DRIVE SYSTEM ADJUSTMENTS 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 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.
CARE AND MAINTENANCE MODEL ZTR 5421 DRIVE SYSTEM ADJUSTMENTS NEUTRAL ADJUSTMENT: Swing upper control levers out into the neutral slots. s; 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 adjustment. If adjustment is required, loosen lock nuts at each end of the control rods and back off the tension on each spring block.
CARE AND MAINTENANCE MODELS ZTR 5501 & ZTR 5601 DRIVE SYSTEM ADJUSTMENTS 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 Tbox.
CARE AND MAINTENANCE MODELS ZTR 5501 & ZTR 5601 DRIVE SYSTEM ADJUSTMENTS 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 to a neutral position h as approximately 1-1/2 to 2 inches of free play.
CARE AND MAINTENANCE MODELS ZTR 5501 & ZTR 5601 DRIVE SYSTEM ADJUSTMENTS NEUTRAL ADJUSTMENT: Swing upper control levers out into the neutral slots. Raise upper body to the fully open po sition. Start engine 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.
CARE AND MAINTENANCE MODELS ZTR 5501 & ZTR 5601 DRIVE SYSTEM ADJUSTMENTS 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 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.
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 replacement parts are available to repair a faulty assembly. The entire clutch must be replaced. A. AIR GAP ADJUSTMENT 1. Remove the clutch from the engine. This is recommended because it is easier to verify the gap. 2.
CARE AND MAINTENANCE - 5000 SERIES MODELS HYDROSTAT IC 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.
CARE AND MAINTENANCE - 5000 SERIES MODELS WHEELS AND TIRES: Correct tire pressure is important for correct operation of mower. Model ZTR 5421 Front Tires Rear tires 11X4X4 18X9.50X8 Air Pressure Air Pressure 16-21 Ibs. 8-14 Ibs. Models ZTR 5501 & ZTR 5601 Front Tires Rear Tires 11X4X5 20X10X8 Air Pressure Air Pressure 16-21 Ibs. 8-14 Ibs. NOTE: Check lug nuts periodically for tightness. ELECTRICAL SYSTEMS: Keep all connections clean and tight. CLEANING THE MOWER: Wash mower periodically.
STANDARD SERVICE PARTS LIST MODEL ZTR 5421: BLADES: BELTS: Standard: HiLift: P/N 6236 P/N 8688 Engine To Mower Deck: Serpentine Belt: Hydrostat Drive Belt: Engine To Drive Pulley: Grass Blower Belt: P/N 6111 P/N 6109 P/N 8772 (set of two) P/N 1860 P/N 4983 Standard: Hi-Lift: P/N 8689 P/N 9265 MODEL ZTR 5501: BLADES: BELTS: Engine To Mower Deck: Serpentine Belt: Engine To T-Box: T-Box To Hydros: Grass Blower Belt: P/N 6111 P/N 1300 P/N 1714 P/N 1765 P/N 4934 MODEL ZTR 5601: BLADES: Hi-Lift: P/N
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.
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 t he above will generally produce a quality cut. The Troubleshooting Chart suggests practices and adjustments that may be helpful in improving cut quality.
TROUBLESHOOTING DRIVE SYSTEM: SITUATION Mower pulls to one side or the other Drive belt from engine to triple pulleys is thrown off when parking brake is engaged to release Drive system will not function on either side after changing hydrostatic transmission oil and filter Drive system functions on one side only Loss of power and speed on both hydrostatic transmissions CAUSES REMEDY Drive adjustment Consult your dealer for repair Faulty belt or incorrect belt is installed * Carefully follow EACH st
TROUBLESHOOTING ELECTRICAL SYSTEM: SITUATION Starter will not turn engine over Starter will not turn engine over Battery discharge Battery discharge Battery discharge NOTE: CAUSES Circuit breaker engaged Dead battery Poor connections on battery Battery water low Wrong battery installed in mower Engine electrical system not functioning correctly Engine being operated at too low an RPM REMEDY Push button to reset Consult your dealer for repair Charge battery Tighten or replace as required Have elect
5421 Drive Pulley/Hydro/Gearbox
5501 T-Box/Hydro/Gearbox
5601 T-Box/Hydro/Gearbox
5000 Series Gearbox
21 Mower Deck
01 Mower Deck
01 Mower Deck
5421 Chassis
5501 Chassis
5601 Chassis
5421 Fuel/Hydro Tanks & Fittings
5501 Fuel/Hydro Tanks & Fittings
5601 Fuel/Hydro Tanks & Fittings
5421 Body
5501 Body
5601 Body
5421 Wiring
5501 Wiring
5601 Wiring
DIXON INDUSTRIES, INC A BLOUNT 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:
