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Summary of Contents for Dixon ZTR 5020
- Page 1 5000 SERIES ® 2002...
- Page 2 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.
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Page 3: Table Of Contents
INDEX Page Safety........4-11 Warranty Policy. -
Page 4: Safety
SAFETY RIDING LAWN MOWERS, 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 BACK OVER ...read and understand this manual to prevent injuries. -
Page 5: Safety Alert Symbol
SAFETY Safety Alert Symbol When you see this symbol, BE ALERT to the potential for injury. Follow recommended safety precautions and safe operating practices. DANGER (highlighted in red) indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING (highlighted in orange) indicates a potentially... -
Page 6: General Operation
SAFETY 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. - Page 7 SAFETY GENERAL OPERATION (continued) : •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 crossingroadways.
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Page 8: Slope Operation
If you cannot back up the slope or if you feel uneasy on it, do not mow it ! • Mow across the slope with your Dixon ZTR - never up or down. • Remove obstacles such as rocks, tree limbs, etc. - Page 9 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. •...
- Page 10 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 fuel cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke while refueling.
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Page 11: Safety
SAFETY SERVICE (continued): • 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. -
Page 12: Warranty Policy
1. Warranty applies only to original retail purchaser of new & 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. -
Page 13: Specifications
SPECIFICATIONS Model ZTR 5020 CHASSIS: 11 GA - rectangular tube BODY: Two piece-made of rotational molded polyethylene. Front body contains access panels for battery service & engine to mower deck belt removal. Rear body tilts up to allow service on the entire drive system. - Page 14 SPECIFICATIONS Model ZTR 5023 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.
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Page 15: Seat Adjustment Instructions
SEAT ADJUSTMENT INSTRUCTIONS 5000 Series Models Grasp seat slide adjuster and move it into adjustment position. Slide seat forward or backward. Release seat slide adjuster. -
Page 16: Controls
CONTROLS CONTROL LEVERS Note: For access to the seat, move control levers to neutral position and swing them outward. TO GO FORWARD: • From neutral position, gently push both control levers forward. • To increase speed, move levers further forward. TO GO BACKWARD: •... -
Page 17: Throttle Control Lever
CONTROLS 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 moving, throttle control should be set to MAXIMUM for wide open setting to insure adequate cooling of the engine and to maintain mower deck blade speed. -
Page 18: Parking Brake
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. CAUTION Engage parking brake before starting engine. TO SET PARKING BRAKE: The hand operated brake is located at the left hand side of the mower. -
Page 19: Blade Drive
CONTROLS BLADE DRIVE: •Located on control panel to operator’s right. To engage blade: Pull up on switch. To disengage blade: Push down. CIRCUIT BREAKER •Located on control panel to operator’s right. •Protection of the electrical system is by (1) 15 amp circuit breaker. •If circuit breaker trips, push button to reset. -
Page 20: Controls
CONTROLS TO FREEWHEEL MACHINE (UNLOCK TRANSMISSION): Move end of by-pass keepers to depress plunger at rear of each hydro pump. Release parking brake. To engage the transmission, move by-pass keepers so plungers return to their normal positions. NOTE: Before pushing or towing tractor, transmission must be unlocked, and parking brake released. -
Page 21: Operation Instructions
OPERATION INSTRUCTIONS The safe and successful operation of the 5000 Series 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 the controls and their functions. -
Page 22: Before Operating Mower
OPERATION INSTRUCTIONS BEFORE OPERATING MOWER: Read and observe all safety instructions on your mower and in the manual. Read engine manufacturer’s operating and maintenance instructions. Discuss proper maintenance with your dealer. Check engine oil. Check fuel cap to be sure it is in place. Be sure parking brake is on. -
Page 23: Testing Of Safety Interlock Systems
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 24: Side Discharge Of The Clippings
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. CAUTION Be sure that the deflector is properly installed on the discharge chute. - Page 25 OPERATION INSTRUCTIONS GRASS HEIGHT AND CUTTING SUGGESTIONS: Do not attempt to cut grass when it is wet. 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.
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Page 26: Starting Instructions
OPERATION INSTRUCTIONS STARTING INSTRUCTIONS (engine has been operated): Move throttle control to 1/4 to 1/2 setting. Insert ignition key and turn to “start” position. When engine starts, release ignition key. Key will return to “run” position. Move throttle control to “fast”... - Page 27 OPERATION INSTRUCTIONS STARTING INSTRUCTIONS (cold engine): Position choke control in “on” position. Position throttle control at 1/2 speed setting. Insert ignition key and turn to “start” position. When engine starts, release ignition key. Key will return to “run” position. Once engine starts to warm up, slowly move choke control to “off”...
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Page 28: Mowing With A Mulching Attachment
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: Set the engine speed control to the wide open... - Page 29 OPERATION INSTRUCTIONS MOWING WITH A MULCHING ATTACHMENT (continued): Keep the Underside Of The Mower Deck Clean. Remove all grass and dirt build-up 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.
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Page 30: Mowing With A Grass Catcher Attachment
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. Set engine speed control to the wide open or full setting. Allow engine, mower deck and blower to reach full RPM before attempting to mow. - Page 31 OPERATION INSTRUCTIONS MOWING WITH A GRASS CATCHER ATTACHMENT (continued): Operate the mower at a slower ground speed than when mowing without a grass catching attachment. Some mowing applications/use of grass catchers may require that an optional weight box be fitted to the mower to counter the weight of grass in the bags.
- Page 32 OPERATION 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.
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Page 33: Care & Maintenance
CARE AND MAINTENANCE CAUTION CAUTION CAUTION CAUTION CAUTION Before perf ore perf ore perfor or or or orming an ore perf ming an ming an ming any maintenance y maintenance y maintenance, tur y maintenance , tur , turn off engine , tur n off engine n off engine, , , , ,... -
Page 34: Care And Maintenance
CARE AND MAINTENANCE ENGINE: For complete maintenance and operating information of the engine, please refer to the maintenance instructions furnished by the engine manufacturer and included in your Zero Turn Radius mower informa- tion packet. BATTERY: Battery contains sulfuric acid electrolyte which is CAUTION poisonous and corrosive. -
Page 35: Cutter Blade Maintenance
CARE AND MAINTENANCE CUTTER BLADE MAINTENANCE: CAUTION Stop engine and remove ignition key for safety. Wear heavy, thick gloves when holding onto cutter blade, avoid the sharp edge of the blade. Check sharpness of mower blades after every 10 hours of operation. Observe proper blade position prior to removal. -
Page 36: Belt Tension
CARE AND MAINTENANCE BELTS: Check belts every 50 hours. Replace any belts found to be in poor condition. BELT TENSION: Engine to Mower Deck Belt: P/N 6111 (50”) P/N 6938 (60”) 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. -
Page 37: Fuel Shut Off Valve
CARE AND MAINTENANCE FUEL SHUT OFF VALVE: The fuel shut off valve is located at the bottom rear of the fuel tank. Always turn the valve to the “OFF” position when the mower is stored or not in use. LUBRICATION: CHASSIS: (5) grease zerks used LOCATIONS:... -
Page 38: Changing The Engine Oil
CARE AND MAINTENANCE Hot oil may cause burns. Allow CAUTION engine to cool before draining oil. CHANGING THE ENGINE OIL: The “Dapco” oil drain valve is located on the left side of the engine crankcase. Place a suitable container under the drain valve. The fitting of a short piece of hose will help direct the oil. -
Page 39: Oil Filters
CARE AND MAINTENANCE OIL FILL: Drain oil. Clean any spilled oil from engine and chassis. Refill engine with type, and quantity of oil recommended by the engine manufacturer in engine literature. OIL FILTERS: Replace filter each time the oil is changed. These filters can be obtained from your authorized engine dealer. - Page 40 Fill new filter with oil (not doing so can cause air pocket in system and possible hydro damage). Install new oil filter to chassis. Use only genuine Dixon replacement oil filter. (Using any other brand of oil filter may not be internally compatible and could cause damage to hydrostat transmission.)
- Page 41 CARE AND MAINTENANCE HYDROSTATIC TRANSMISSION OIL & FILTER SERVICE (continued): Depress by-pass valve on both hydros. Start engine and move throttle to mid-range setting. Release parking brake. Dirty oil, filled with air bubbles, will start to drain from oil return hoses into container.
- Page 42 CARE AND MAINTENANCE HYDROSTATIC TRANSMISSION OIL & FILTER SERVICE: Dirt or water in oil can ruin the hydrostatic transmissions. SERVICE INTERVALS: 1. Initial filter service - 50 hours 2. Every 250 hours or once a year thereafter. OIL REQUIREMENTS: Any high quality engine oil with an API classification of SG/CD is recommended.
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Page 43: Cleaning The Mower
WARRANTY: See Warranty Registration Form-P/N 8288 (sample on page 12). PARTS/SERVICE: See your Dixon dealer for replacement parts, warranty or service. PLEASE HELP PROTECT THE ENVIRONMENT BY AVOIDING ALL CHEMCIALS WHICH MAY DAMAGE OR CAUSE HARM TO PLANTS AND ANIMALS IN YOUR AREA. -
Page 44: Mower Deck Leveling Procedure
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 locknuts on the bottom which can be turned up or down to raise or lower the front and rear of the mower deck. - Page 45 CARE AND MAINTENANCE MOWER DECK LEVELING PROCEDURE (continued): 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 1/8” higher in the rear than the side-to-side measurement.
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Page 46: Mower Deck Removal
CARE AND MAINTENANCE MOWER DECK REMOVAL: 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. Insert end of link here 5283... - Page 47 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 free play or move- ment at a mid-point between the pulleys on the hydrostats and T-Box.
- Page 48 CARE AND MAINTENANCE PARKING BRAKE CABLE ADJUSTMENT: Make necessary adjustments to the T-Box to Hydrostat belt, as shown on page 47. 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.
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Page 49: Rear Wheels
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. -
Page 50: Neutral Adjustment
CARE AND MAINTENANCE NEUTRAL ADJUSTMENT: Engage parking brake and raise rear of frame with jack or blocks so that rear tires do not contact the ground. Swing out the control levers, start the engine, and release the paking brake. Raise the upper body to access hydro control linkage. If right wheel creeps, adjust right side linkage and vice-versa. - Page 51 CARE AND MAINTENANCE NEUTRAL ADJUSTMENT(continued): 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. 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.
- Page 52 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.
- Page 53 CARE AND MAINTENANCE PROCEDURE FOR ELECTRIC CLUTCH ADJUSTMENT (CONTINUED): B. OHMS TEST Disconnect clutch from mower wiring harness. Attach the two leads on multi-meter to the two wires coming from the electric clutch. The reading you receive should be between 2.5 to 4.0 OHMS.
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Page 54: Care & Maintenance
CARE AND MAINTENANCE FORWARD TRAVEL SPEED ADJUSTMENT: Drive machine on a smooth surface with both levers in top speed position. 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. -
Page 55: Standard Service Parts List
STANDARD SERVICE PARTS LIST 50” Deck Blades: Hi-Lift - P/N 9444 (Standard) Lo-Lift - P/N 9443 Belts: Engine to Mower Deck - P/N 6111 Serpentine - P/N 1300 Engine to T-Box - P/N 7253 T-Box to Hydros - P/N 1765 Grass Blower Belt - P/N 4983 60”... -
Page 56: Troubleshooting
TROUBLESHOOTING ENGINE WON’T TURN OVER Mower blades engaged- - - - - - - - - - - - - - - - - - - - - - -disengage blades Drive not in neutral - - - - - - -move control levers to neutral “OUT” Circuit breaker trips- - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - reset breaker Dead battery- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - charge or replace Solenoid- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer... - Page 57 TROUBLESHOOTING ENGINE RUNS BUT MOWER WON’T MOVE FORWARD Drive belt broken or slipping- - - - - - - - - - - - - - - - - - - - replace drive belt Transmission oil low- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - -add oil Transmission locks in free-wheel position- - - - lock position( see pg.20) Hydrostat oil filter plugged- - - - - - - - - - - - - - - - - - - - - - - - - - -replace filter...
- Page 58 NOTES...
- Page 59 OWNER INFORMATION DIXON INDUSTRIES, INC. a BLOUNT International Inc. Co. P.O. Box 1569 Coffeyville, Ks 67337-0945 620-251-2000 FAX 620-251-4117 Date Purchased _________________________________ Mower Model Number ____________________________ Mower Serial Number ____________________________ Purchased From ________________________________ Name ________________________________ Address ________________________________ DATE OIL CHANGED:...
- Page 60 ARNING: ARNING: ARNING: to the State of California to cause cancer, birth defects or other reproductive harm. Dixon® and ZTR® are registered trademarks of Dixon Industries, Inc. DIXON INDUSTRIES, INC. a BLOUNT International Inc. Co. P.O. Box 1569 5000 Series Coffeyville, Ks 67337-0945 5020 &...
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