Dixon ZTR 5023 manual

1 Page 2000 Operator's Manual 5000 SERIES[...]

Page 2 IMPORT ANT - READ CAREFULL Y 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 st art to use the mower , read the operator's manual carefully and become completely familiar with the controls. The information in th[...]

3 Page INDEX SAFETY .......................................................... Pages 2 - 7 W ARRANTY POLICY ..................................... Page 8 SPECIFICA TIONS .......................................... Pages 9 - 1 1 SEA T ADJUSTMENT ..................................... Page 12 CONTROLS ....................................................[...]

Page 4 ...read and understand this manual to prevent injuries. TIP-OVER BACK-OVER RUN-OVER BLADE CONTACT SAFETY RIDING LA WNMOWERS, IF IMPROPERL Y OPERA TED, CAN CAUSE SERIOUS INJUR Y OR DEA TH The most common causes of injury to the operator or bystander ...[...]

5 Page SAFETY SAFETY SYM BOLS 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. W arning indicates a potentially hazardous situation [...]

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 SAFETY SLOPE OPERA TION: 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 a[...]

Page 8 SAFETY 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 st ay where they were last seen. Be alert to avoid accident s. • Keep children out of the mowing area and under the watchful care of another respon[...]

9 Page 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 b[...]

Page 10 DIXON LIMITED W ARRANTY POLICY -- EST A TE 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 a[...]

11 Page SPECIFICA TIONS Model ZTR 5020 CHASSIS: 1 1 G A - 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 SPECIFICA TIONS Model ZTR 5425 CHASSIS: 1 1 G A - 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 14 SEA T 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 .[...]

15 Page CONTROLS[...]

Page 16 CONTROLS P ARKING BRAKE: CAUTION Engage parking brake before starting engine 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. TO 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[...]

17 Page CONTROLS (left turn opposite) TO GO FOR W ARD: From neutral position, gently push both drive levers forward. To increase speed, move levers farther forward. TO 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 [...]

Page 18 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. If circuit breaker trips, push button to reset. If this [...]

19 Page OPERA TION INSTRUCTIONS 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, "l[...]

Page 20 OPERA TION INSTRUCTIONS 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 sta[...]

21 Page OPERA TION INSTRUCTIONS ST AR TING 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 , sl[...]

Page 22 OPERA TION INSTRUCTIONS MOWING WITH A MULCHING A TT ACHMENT : 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 achi[...]

23 Page OPERA TION INSTRUCTIONS MOWING WITH A GRASS CA TCHER A TT ACHMENT : 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 und[...]

Page 24 OPERA TION INSTRUCTIONS 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 yo[...]

25 Page OPERA TION INSTRUCTIONS 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 s[...]

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 MOWER BLADE MAINTENANCE : NOTE: Observe proper blade position prior to removal. 1 . Safely raise front of mower. 2 . Hold or block blade from turning. 3. Loosen blade nut and remove blade. 4 . When replacing blade, tighten blade nut securely. Refer to diagram. CAUTION Wear heavy, thick gloves when holding onto mower bla[...]

Page 28 REAR HANGER PIN BEL T TENSION ENGINE TO MOWER 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. MOWER DECK SERPENTINE BEL T : 42 " P/N 6109 5[...]

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. LUBRICA TION CHASSIS: Number of grease zerks used: (5) LOCA TIONS: (1) each front wheel caster tube (1) each mower deck hub SER VICE [...]

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 "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 [...]

Page 32 CARE AND MAINTENANCE MOWER DECK REMOV 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 dec[...]

33 Page CARE AND MAINTENANCE MOWER DECK LEVELING PROCEDURE: There are a total of (4) threaded adjusters which will control the attitude or pitch of the mower deck. The adjusters have lock nuts on the bottom which can be turned up or down to raise or lower the front and rear of the mower deck. Deck should be level or pitched slightly higher in rear.[...]

Page 34 CARE AND MAINTENANCE Adjustment of the drive system is limited to the actual function of the hydrostatic transmissions as outlined below. T -BOX 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. ADJUST HERE FOR PROPER FREE PLAY OF CABLE WITH BRAKE LEVER OFF P ARKING BRAKE CABLE ADJUSTMENT : Make necessary adjustments to the T-Box to Hydrostat belt, as shown on page 32. [...]

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 rem[...]

37 Page CARE AND MAINTENANCE FORW 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 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 [...]

39 Page CARE AND MAINTENANCE HYDROST A TIC TRANSMISSION OIL AND FIL TER SERVICE SERVICE INTERVALS: 1 . Initial oil and filter service - 50 hours. 2 . Every 250 hours thereafter. OIL REQUIREMENTS: Any high quality engine oil with an API classification of SG/CD is recommended. RECOMMENDED OIL WEIGHT: Normal operation temperatures - 20 W 50 Cold clima[...]

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 ARTS LIST 42" DECK BLADES: L o L i f t P/N 6236 S t andard Hi-Lif t P/N 8688 B E LT S : Engine to Mower Deck P/N 61 1 1 Serpentine Belt P/N 6109 Engine to T -Box P/N 7253 T -Box to Hydros P/N 1765 Grass Blower Belt P/N 4983 50" DECK BLADES: Lo-Lif t P/N 9443 S t andard Hi-Lif t P/N 9444 B E LT S : Engine to Mo[...]

43 Page ST ANDARD SER VICE P ARTS LIST KOHLER AND BRIGGS & STRA TTON 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 23HP Pre-Cleaner [...]

Page 44 SITUATION CAUSES REMEDY Poor cut quality Ground speed Reduce mowing speed. Poor cut quality Incorrect engine to Refer to page 40 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 35 for procedure side or the other speed adjustment or consult your dealer for repair. TROUBLESHOOTING 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 o[...]

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

47 Page NOTES[...]

Page 48 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 DM- Name DATE OIL CHANGED: DATE ENGINE TUNED: MOWER SERIAL NUMBER PURCHASED FROM OWNER INFORMA TION[...]

49 Page Dixon ® and ZTR ® are registered trademarks of Dixon Industries, Inc. 5000Series 5020,5023&5425 Part No. 1858-0599 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 def[...]