Dixon Lawn Mower ZTR 5017 User Manual

1999 Operator's Manual  
5000  
SERIES  
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INDEX  
SAFETY .................................................................Pages 2 - 7  
WARRANTYPOLICY..............................................Page  
SPECIFICATIONS..................................................Page 10 - 12  
SEAT ADJUSTMENT.............................................Page 13  
8 - 9  
CONTROLS ...........................................................Pages 14 - 17  
OPERATIONINSTRUCTIONS ................................Pages 18 - 24  
CARE AND MAINTENANCE..................................Pages 25 - 40  
STANDARD SERVICE PARTS LIST......................Page 41 - 42  
TROUBLESHOOTING ............................................Pages 43 - 45  
5000 Series  
Part No. 8965-0798  
a
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SAFETY  
RIDING LAWNMOWERS, IF IMPROPERLY OPERATED,  
CAN CAUSE SERIOUS INJURY OR DEATH  
The most common causes of injury to the operator or bystander...  
BLADECONTACT  
TIP-OVER  
BACK-OVER  
RUN-OVER  
...read and understand this manual to prevent injuries.  
Page 4  
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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.  
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 avoided, may result in minor or  
moderate injury. It may also be used to alert  
against unsafe practices.  
Page 5  
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SAFETY  
This cutting mower is capable of amputating hands & 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 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 & unloading.  
The engine exhaust from this product contains chemicals known to the  
State of California to cause cancer, birth defects or other reproductive harm.  
WARNING:  
Page 6  
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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 catchers 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  
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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. 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, shrubs, trees, or other objects that may  
obscure vision.  
Page 8  
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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 area. The exhaust fumes are toxic.  
Keep nuts and bolts tight, especially blade attachment bolts, and keep equipment in  
good condition.  
Never tamper with safety devices. Check their proper operation regularly.  
Keep mower free of grass, leaves, or 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 and replace with original equipment parts, when necessary.  
Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and use extra  
caution when servicing them.  
Batteries contain sulfuric acid. To 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  
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DIXONLIMITEDWARRANTYPOLICY--HYDRO-GEARMODELS  
ThiswarrantypolicyappliestoallCommercialHydrostaticmowers,purchasedonorafterMarch1,1990.  
WARRANTY:DixonWarrantytermisforaperiodofone(1) year fromdateofpurchaseor400hoursof  
use,whicheveroccursfirst.Mowersusedforresidentialhomeowner applications (usedonlyatowner's  
primaryplaceofresidence)arewarrantedfortwo(2)yearsfromdateofpurchase 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.  
2.  
Warrantyappliesonlytooriginalretailpurchaserofnewandunusedmowersandaccessories.  
AllDixonwarrantymustbeaccomplishedbyauthorizedDixondealersandinaccordancewithDixonwarrantypolicy  
andallowances.AllwarrantyclaimsmustbeapprovedbyDixonIndustries,Inc.  
3.  
4.  
5.  
Batterywarranty:Limitedto90daysfromdateofpurchase.  
AccessoriesWarranty(GrassCatchers,SnowBlades,TineRakes,Covers,etc.):Limitedto90daysfromdateofpurchase.  
Warrantydoesnotapplytodamageintransitorincidentsofmisuse,negligence,accidents,oralteration.Theuseofparts  
or componentsotherthanthosesuppliedbyDixonIndustries,Inc.VOIDSALLWARRANTY.  
6.  
Thefollowingitemsarenotcoveredbythiswarrantypolicy:  
(a)PickupanddeliverychargesfortransportationofmowertoandfromanAuthorizedDixonDealer'splaceofbusiness.  
(b)Routinemaintenanceoradjustments.  
(c) Belts/chains/sprockets/cuttingblades.  
(d)Engines--AllenginesusedonDixonZTRmowersarewarrantedbyeachindividualenginemanufacturer.  
(e)Anycostsorexpenseofprovidingsubstituteequipmentwhilerepairworkisbeingperformedonawarrantedmower.  
7.  
Thereisnootherexpresswarranty.Impliedwarranties,includingthoseofmerchantabilityandfitnessforaparticular  
purpose, arelimitedtothesamedurationoftheexpresswarranty,andtotheextentpermittedbylawanyandallimplied  
warrantiesareexcluded.Liabilitiesforconsequentialdamagesunderanyandallwarrantiesareexcluded.  
WARRANTYVALIDATION:Atthetimeofsale,sellingdealermustrevieweachportionofthiswarrantydocument,complete  
theinformationsectionbelow,securecustomer'ssignatureandsendcopytoDixonIndustries,Inc.  
DM-  
DateofPurchase  
Model  
S/N  
(Owner'sName)  
(Address)  
(Dealership)  
(Address)  
(Dealer'sSignature)  
(Owner'sSignature)  
SEE DEALER FOR DETAILS  
Page 10  
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DIXON LIMITED WARRANTY 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. All Dixon 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. Batterywarranty:Limitedto90days fromdateofpurchase.  
4. AccessoriesWarranty(GrassCatchers, SnowBlades, TineRakes, Covers, etc.):Limitedto 90daysfromdateofpurchase.  
5. Warrantydoesnotapplytodamageintransitorincidentsofmisuse,negligence,accidents,oralteration.Theuseofparts  
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) Routinemaintenanceoradjustments.  
(c) Belts/cuttingblades/HydroGearFilters.  
(d) Engines -- All engines used on Dixon ZTR mowers are warranted by each individual engine manufacturer.  
(e) Any costs or expense of providing substitute equipment while repair work is being performed on a warranted mower.  
7. Thereisnootherexpresswarranty.Impliedwarranties,includingthoseofmerchantabilityandfitnessforaparticular  
purpose, are limited to the same duration of the express warranty, and to the extent permitted by law any and all implied  
warranties are excluded. Liabilities for consequential damages under any and all warranties are excluded.  
WARRANTYVALIDATION:Atthetimeofsale,sellingdealermustrevieweachportionofthiswarrantydocument,completethe  
information section below, secure customer's signature and send copy to Dixon Industries, Inc.  
DATE OF PURCHASE__________________________Model ____________________ S/N______________________  
(Owner'sName)  
(Address)  
(Dealership)  
(Address)  
(Owner's Signature)  
(Dealer'sSignature)  
SEE DEALER FOR DETAILS  
Page 11  
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SPECIFICATIONS  
Model ZTR 5017  
CHASSIS:  
BODY:  
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.  
SEAT:  
Designed for operator comfort by use of high density closed cell foam padded  
back and arm rests, upholstered with CorduraTM water-repellent fabric. Seat is  
adjustable fore and aft.  
MOWER DECK:  
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  
BLADEDRIVE:  
Electric clutch  
DRIVE SYSTEM:  
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.  
ENGINE:  
17HP Briggs & Stratton Intek, overhead valves, replaceable oil filter, full  
pressure lube system, dual element air cleaner, impulse fuel pump  
STARTINGSYSTEM:  
TIRES:  
Electric by key switch operation with safety interlocks on parking brake and  
blade drive clutch.  
Front  
Rear  
11 X 4 X 5 smooth profile  
20 X 10.5 X 8 Multi Trac  
RECOMMENDED  
TIREPRESSURE:  
Front  
Rear  
16 - 21 lbs.  
8 - 14 lbs.  
CAPACITIES:  
DIMENSIONS:  
NOTE:  
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"  
45"  
72"  
615 lbs.  
Height  
Length  
Weight  
Additionalinformationprovidedinserviceinstructionsundertheindividualcomponent.  
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE  
Page 12  
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SPECIFICATIONS  
Model ZTR 5020  
CHASSIS:  
BODY:  
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.  
SEAT:  
Designed for operator comfort by use of high density closed cell foam padded  
back rest and arm rests, upholstered with CorduraTM water-repellent fabric.  
Seat is adjustable fore and aft.  
MOWER DECK:  
3 Decks are available. 42" & 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  
BLADEDRIVE:  
Electric clutch  
DRIVE SYSTEM:  
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.  
ENGINE:  
20HP Briggs & Stratton Intek, overhead valves, replaceable oil filter, full  
pressure lube system, dual element air cleaner, integral fuel pump.  
STARTINGSYSTEM:  
TIRES:  
Electric by key switch operation with safety interlocks on parking brake and  
blade drive clutch.  
Front  
Rear  
11 X 4 X 5 smooth profile  
20 X 10.5 X 8 Multi Trac  
RECOMMENDED  
TIREPRESSURE:  
Front  
Rear  
16 - 21 lbs.  
8 - 14 lbs.  
CAPACITIES:  
DIMENSIONS:  
NOTE:  
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"(42" Deck), 60"(50" Deck), 73"(60"Deck)  
45"  
72"  
Height  
Length  
Weight  
630 lbs.(42" Deck), 668 lbs. (50" Deck), 685 lbs. (60" Deck)  
Additional information provided in service instructions under the individual  
component.  
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE  
Page 13  
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SPECIFICATIONS  
Model ZTR 5022  
CHASSIS:  
BODY:  
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.  
SEAT:  
Designed for operator comfort by use of high density closed cell foam padded  
back and arm rests, upholstered with CorduraTM water-repellent fabric. Seat is  
adjustable fore and aft.  
MOWER DECK:  
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  
BLADEDRIVE:  
Electric clutch  
DRIVE SYSTEM:  
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.  
ENGINE:  
22HPKohlerCommand,4-Cycle,V-Configuration,OverheadValve,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  
Carburetorw/Smart-Choke,ElectronicIgnition,In-LineFuelFilter,DualElement  
Air Cleaner.  
STARTING SYSTEM:  
TIRES:  
Electric by key switch operation with safety interlocks on parking brake and  
blade drive clutch.  
Front  
Rear  
11 X 4 X 5 ribbed tread  
20 X 10 X 8 Multi Trac  
RECOMMENDED  
TIRE PRESSURE:  
Front  
Rear  
16 - 21 lbs.  
8 - 14 lbs.  
CAPACITIES:  
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)  
DIMENSIONS:  
Width  
51"(42" Deck), 60"(50" Deck), 72"(60" Deck)  
45"  
72"  
Height  
Length  
Weight  
615 lbs.(42" Deck), 680 lbs.(50" Deck), 685 lbs.(60" Deck)  
NOTE:  
Additionalinformationprovidedinserviceinstructionsundertheindividualcomponent.  
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE  
Page 14  
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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.  
Page 15  
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CONTROLS  
Page 16  
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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.  
.
Engage parking brake before starting engine  
CAUTION  
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  
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CONTROLS  
(left turn opposite)  
From neutral position, gently push both drive levers forward.  
To increase speed, move levers farther forward.  
TO GO BACKWARD:  
From neutral position, gently pull both drive levers toward you.  
TURNING:  
Turning is controlled by moving one drive lever slightly forward or rearward of the other.  
To turn left, move left lever 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.  
BRAKING:  
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:  
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.  
Page 18  
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CONTROLS  
BLADE DRIVE:  
Located on control panel, on operator's right.  
To engage blades: Pull up on the switch.  
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.  
Ifcircuitbreakertrips,pushbuttontoreset.  
If this condition repeats, consult dealer for  
inspection and repair.  
MOWER DECK CUT HEIGHT LIFT LEVER:  
Located to the right and front of operator.  
Controlsthecuttingheight.  
Sevenpositionsofadjustment.  
Depress trigger and move lever forward to  
lowerdeck.  
Depress trigger and pull lever back to raise  
deck.  
NOTE: Always use high position for transport.  
Page 19  
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OPERATIONINSTRUCTIONS  
Safeandsuccessfuloperationwilldependupontheoperatorhavingthecorrect knowledgeofall  
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, "learning to drive", set throttle at slow speed.  
Soundjudgementbytheoperatorwillpreventaccidents.  
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. Readenginemanufacturer'soperatingandmaintenanceinstructions.  
2. Discusspropermaintenancewithyourdealer.  
3. Readandobserveallsafetyinstructionsonyourmowerandinthemanual.  
4. Check engine 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  
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OPERATIONINSTRUCTIONS  
TESTING OF SAFETY INTERLOCK SYSTEMS:  
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  
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OPERATIONINSTRUCTIONS  
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.  
Key will return to "Run" position.  
4. Once engine starts to warm up, slowly move  
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:  
Engine has been operated.  
1. Move throttle control 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 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.  
CAUTION DO NOT operate the engine in an enclosed area. The exhaust fumes are toxic.  
Page 22  
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OPERATIONINSTRUCTIONS  
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.  
2.  
Set the engine speed control to the wide open or full setting.  
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.  
4.  
5.  
6.  
7.  
It may be necessary to cut the lawn twice to achieve acceptable mulching performance  
especially on first cuttings or if the lawn is heavily fertilized.  
Do Not Attempt To Cut Grass When It Is Wet. Mulching performance will be very poor under  
wet grass conditions.  
Maintain Sharp Blades Throughout The Cutting Season. This is very important. Optimal  
mulching performance cannot be obtained with dull or nicked blades.  
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.  
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.  
2.  
3.  
4.  
5.  
6.  
Raise the height-of-cut setting on your mower.  
It may be necessary to cut your grass more frequently.  
Operate the mower at a slower ground speed.  
Overlap cutting swaths instead of cutting a full swath with each pass.  
Mow across the marginal areas a second time.  
CUT HIGH - MOW OFTEN!  
Page 23  
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OPERATIONINSTRUCTIONS  
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.  
3.  
4.  
5.  
If the grass is tall, 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.  
6.  
7.  
Maintain Sharp Blades Throughout The Cutting Season.  
Operate the mower at a slower ground speed than when mowing without a grass catching  
attachment.  
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  
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OPERATIONINSTRUCTIONS  
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.  
Besurethatdeflectorisproperlyinstalledonthe  
dischargechute.  
CAUTION  
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  
Blue Grass  
Fescue Blends  
St. Augustine (Mid South)  
St. Augustine (Deep South)  
Tifton Bermuda  
2" - 2 1/2"  
1 1/2" - 3"  
1 1/2" - 3"  
1 1/2" - 2"  
3" - 4"  
1 1/2"  
Centipede  
Common Bermuda  
Bahia/Argentina/Pensacola  
1 1/2" - 2"  
1 1/2" - 2"  
2"  
Page 25  
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OPERATIONINSTRUCTIONS  
DECK ROLLERS:  
60" Deck  
Purpose:  
Height:  
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.  
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.  
Page 26  
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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.  
MAINTENANCESCHEDULE:  
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 asterisk * require more frequent attention)  
1.  
2.  
3.  
4.  
5.  
6.  
Drive system, belts and controls.  
Mower deck belts.  
Tire pressures.  
HydroGear oil tank.  
Tightness of all nuts and bolts.  
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.  
CAUTION  
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-SEASONBATTERYSTORAGE:  
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  
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CARE AND MAINTENANCE  
MOWERBLADEMAINTENANCE:  
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  
sharp edge of the blade.  
CAUTION  
NOTE: Be sure blade is centered on pilot before tightening nut to 60 ft. lbs. torque.  
Page 28  
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CARE AND MAINTENANCE  
BELT TENSION  
ENGINE TO MOWER DECK BELT:  
42' and 50"  
60"  
P/N 6111  
P/N 6938  
The engine to mower deck drive belts are automatically held in proper tension by springs  
whichpushthedeckassemblyforwardanddonotrequireanyadditionaladjustmenttobe  
made.  
MOWER DECK SERPENTINE BELT:  
42"  
P/N 6109  
P/N 1300  
P/N 6939  
50"  
60"  
Refer to illustration for adjustment procedure.  
TIGHTENORLOOSEN  
HEXNUTTOACHIEVE  
THISDIMENSION  
50" & 60"  
42"  
5/8"  
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  
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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:  
Number of grease zerks used: (5)  
LOCATIONS:  
(1) each front wheel caster tube  
(1) each mower deck hub  
SERVICEINTERVALS:  
Every 50 hours of operation  
RECOMMENDEDGREASE:  
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.  
Page 30  
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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 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.  
WHEELREVERSAL:  
* 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. lbs.  
Page 31  
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CARE AND MAINTENANCE  
HOToilmaycauseburns.  
Allowenginetocoolbeforedrainingoil.  
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 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  
CLOSED  
OPEN  
8429  
OILFILL:  
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.  
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  
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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.  
INSERTENDOF  
LINK HERE  
5283  
LINK  
FRONTOF  
LIFT  
FRAME  
2. Remove front and rear deck hanger pins, as illustrated below.  
REAR  
HANGER  
PIN  
FRONT  
HANGER  
PIN  
3. Slide deck from beneath chassis.  
4. Reverse procedure to reinstall deck to chassis.  
Page 33  
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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.  
A. Placethemoweronasmoothlevelsurface, checktirepressurestoinsurethemower  
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.  
C. Measure from the floor surface up to the bottom of the blade tip on the discharge side  
of the 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.  
D. 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. At this 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.  
E. 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 type of grass or  
conditions being mowed.  
FRONT  
ADJUSTERS  
LEFTREAR  
ADJUSTER  
DECKLEVELINGADJUSTMENTPOINTS  
Page 34  
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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-BOXBELTTENSION  
Å Bypass Relief Pin  
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  
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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.  
ADJUSTHEREFOR  
PROPER FREE PLAY OF  
CABLE WITH BRAKE  
LEVER OFF  
NOTE:  
Cablemusthavetherecommended1-1/2to2inchesoffreeplaywithparking  
brake released or drive belt may slip, causing loss of power.  
Page 36  
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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. Raise the 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  
9067CONTROLROD  
ADJUST IN STEP C  
d. tighten jam nuts on control rod  
5540CONTROL  
e. tighten bolt in control tube  
TUBE  
JAM NUTS  
LOOSEN  
INSTEPBTIGHTENIN  
STEPD  
CONTROLTUBEBOLT  
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  
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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 control lever mounting nut. Rotate lever to be even  
with other side and tighten nut.  
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  
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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  
1. It is not necessary to remove the clutch from the motor.  
2. Locate the three holes in the brake plate, one near each  
adjustment nut. (figure 1)  
Figure 1  
3. Insert a .012 inch feeler gauge into one of the three  
windows. Be careful to position the feeler gauge  
between the rotor and armature faces. (figure 2)  
4. 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.  
Figure 2  
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  
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CARE AND MAINTENANCE  
HYDROSTATIC TRANSMISSION OIL AND FILTER SERVICE  
SERVICEINTERVALS:  
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.  
OILFILTER:  
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 a "pressure"  
to allow oil flow. Usage will  
result in an "air-lock" condition  
with possible damage.  
Page 40  
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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. Remove oil filter from chassis, allowing oil to drain into container. Clean impurities from inside  
of reservoir, if necessary.  
2. Install new oil filter to chassis. Use only genuine Dixon replacement oil filter.  
3. Put fresh oil in reservoir. Fill reservoir to the full mark.  
4. Remove two oil return hoses from top of oil reservoir and direct these hoses into a container for  
oil draining.  
5. Depress by-pass valve on both hydros.  
6. Start engine and move throttle to mid-range setting.  
7. Release parking brake.  
8. 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.  
9. 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  
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CARE AND MAINTENANCE  
WHEELS AND TIRES:  
Correct tire pressure is important for correct operation of  
mower.  
Front Tires  
Rear Tires  
11 x 4 x 5  
20 x 10.5 x 8 8-14 lbs.  
16-21 lbs.  
NOTE: Check lug nuts periodically for tightness.  
ELECTRICALSYSTEMS:  
CLEANING THE MOWER:  
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.  
SERIALNUMBERS:  
WARRANTY:  
The serial number is located on frame at rear of engine.  
Refer to Warranty Registration Form.  
PARTS/SERVICE:  
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 42  
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STANDARD SERVICE PARTS LIST  
42" DECK  
BLADES:  
Lo Lift:  
Standard Hi-Lift:  
P/N 6236  
P/N 8688  
BELTS:  
Engine To Mower Deck:  
Serpentine Belt:  
Engine To T-Box:  
T-Box To Hydros:  
Grass Blower Belt:  
P/N 6111  
P/N 6109  
P/N 7253  
P/N 1765  
P/N 4983  
50"DECK  
BLADES:  
BELTS:  
Lo Lift:  
Standard Hi-Lift:  
P/N 9443  
P/N 9444  
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 7253  
P/N 1765  
P/N 4983  
60"DECK  
BLADES:  
BELTS:  
Hi-Lift:  
P/N 9445  
Engine To Mower Deck:  
Serpentine Belt:  
Engine To T-Box:  
T-Box To Hydros:  
P/N 6938  
P/N 6939  
P/N 7253  
P/N 1765  
Page 43  
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STANDARD SERVICE PARTS LIST  
KOHLER AND BRIGGS & STRATTON 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.  
Kohler  
22HP  
Pre-Cleaner Foam Element  
Cartridge Air Cleaner  
Engine Oil Filter  
45083-01  
45083-02  
12050-01  
Briggs & Stratton  
Briggs & Stratton  
20HP  
Pre-Cleaner Foam Element  
Cartridge Air Cleaner  
Engine Oil Filter  
273638  
499486  
492932  
17 HP  
Pre-Cleaner Foam Element  
Cartridge Air Cleaner  
Engine Oil Filter  
272403  
496894  
492932  
Page 44  
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TROUBLESHOOTING  
MOWER CUT QUALITY:  
There are many variables that can affect the cut quality of any riding mower. Type and  
conditionsofgrass, cutheightsetting, engineRPMandgroundspeedaresomeofthevariables  
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  
CAUSES  
REMEDY  
Poor cut quality  
Poorcutquality  
Ground speed  
Reduce mowing speed  
Refer to page 40 for part numbers  
Incorrectengineto  
mower deck belt  
Poor cut quality  
Poor cut quality  
Poorcutquality  
Engine RPM too low  
Dull or bent blade  
Increase engine RPM to maximum  
Sharpen or replace as required  
Un-levelmowerdeck  
Refer to page 31 for deck leveling  
procedure  
Poor cut quality  
Poorcutquality  
Poorcutquality  
Grass buildup under  
mower deck  
Clean out underside of mower deck  
Refer to page 40 for part numbers.  
Improperblades  
Uneventirepressures  
Refer to page 39 for correct tire  
pressures.  
Page 45  
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TROUBLESHOOTING  
DRIVE SYSTEM:  
SITUATION  
CAUSES  
REMEDY  
Mower pulls to one  
side or the other  
Forwardtravel  
speed adjustment  
Refer to page 35 for procedure  
or consult your dealer for repair  
Drivesystemwillnot  
function on either side  
after changing  
Incorrectoilfilterinstalled Replace with correct Dixon  
onsystem  
filter  
hydrostatic transmission Hydrostatic  
Consult your dealer for repairs  
Continued attempted operation  
may result in damage to the  
system  
oil and filter  
transmissions are "air  
locked", low or no oil  
return to tank  
Drive system functions  
on one side only  
Loss of set screw tension Consult your dealer for repairs  
on hydrostatic  
transmission pulley  
Loss of power and speed Incorrect parking brake  
Refer to adjustment procedure  
page 33 or consult your dealer  
for repair  
on both hydrostatic  
transmissions  
cable adjustment  
Incorrect or worn drive  
belt  
Replace with correct belt  
Neutral adjustment  
Mower creeps in  
neutral position  
Refer to adjustment procedure page  
34 or consult your dealer  
for repair  
Page 46  
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TROUBLESHOOTING  
ELECTRICAL SYSTEM:  
SITUATION  
CAUSES  
REMEDY  
Starter will not  
turn engine over  
Circuit breaker  
disengaged  
Push button to reset  
Consult your dealer for repair  
Starter will not  
Dead battery  
Charge battery  
turn engine over  
Battery discharge  
Poor connections on  
battery  
Tighten or replace as required  
Battery water low  
Wrong battery installed  
in mower  
Battery discharge  
Battery discharge  
Engine electrical system Have electrical system checked by  
not functioning correctly your dealer  
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,  
looseconnections,corrosion,frayedorbrokenwiring,aremorelikelythancomponent  
failure.  
Page 47  
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NOTES  
P8  
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DIXONINDUSTRIES,INC.  
ABLOUNTInternationalInc.Co.  
PO BOX 1569  
COFFEYVILLEKS 673370945  
316 251 2000  
FAX 316 251 4117  
OWNER  
INFORMATION  
DATE PURCHASED  
MOWER MODEL NUMBER  
PURCHASED FROM  
Name  
Address  
DM-  
MOWER SERIAL NUMBER  
DATE OIL CHANGED:  
DATE ENGINE TUNED:  
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The engine exhaust from this product contains chemicals known to the  
State of California to cause cancer, birth defects or other reproductive  
harm.  
WARNING:  
Dixon® and ZTR® are registered trademarks of Dixon Industries, Inc.  
DIXON INDUSTRIES, INC.  
A BLOUNT International Inc. Co.  
PO BOX 1569  
COFFEYVILLE KS 67337 0945  
316 251 2000  
5000Series  
Part No. 8965-0798  
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