Dixon 13089-0601 - Manuals

5 Safety Alert Symbol When you see this symbol, BE ALERT to the potential for injury. 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 hazardous situation whi...

6 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 mo...

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. • Keep children out of the mowing area and un...

12 DIXON INDUSTRIES, INC.a BLOUNT companyAirport Industrial ParkP.O. Box 1569Coffeyville, Ks 67337- 0945620-251-2000Fax 620-251-4117 DIXON LIMITED WARRANTY POLICY - ESTATE MODELS 5000 Series WARRANTY: Home Owner Application: This Dixon Warranty term is for a period of two (2)yearsfrom date of purcha...

13 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 allowservice on the entire drive system. SEAT: Designed for ...

15 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.

16 CONTROLS CONTROL LEVERS Note: For access to the seat, move control levers to neutral position andswing them outward. TO GO FORWARD: • From neutral position, gently push both control levers forward. • To increase speed, move levers further forward. TO GO BACKWARD: • From neutral position, gently p...

17 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 se...

18 CONTROLS PARKING BRAKE: The parking brake is designed to hold the mower from moving and isnot intended for use in stopping the mower while it is in motion. CAUTION Engage parking brake beforestarting engine. TO SET PARKING BRAKE: The hand operated brake is located at the left hand side of the mow...

19 CONTROLS MOWER DECK CUT HEIGHT LIFT LEVER: • Located to the right and front of operator. • Controls the cutting height. • Seven positions of adjustment. • Depress trigger and move lever forward to lower deck. • Depress trigger and pull lever back to raise deck. NOTE: Always use high position for ...

20 CONTROLS TO FREEWHEEL MACHINE (UNLOCK TRANSMISSION): Move end of by-pass keepers to depress plunger at rearof each hydro pump. Release parking brake. To engage the transmission, move by-pass keepers soplungers return to their normal positions. NOTE: Before pushing or towing tractor, transmission ...

21 OPERATION INSTRUCTIONS The safe and successful operation of the 5000Series will depend upon the operator having thecorrect knowledge of all controls used on themower and making good judgements about theterrain to be mowed. NEVER allow anyone to operate the mower withoutcomplete knowledge of all t...

22 BEFORE OPERATING MOWER: 1. Read and observe all safety instructions on yourmower and in the manual. 2. Read engine manufacturer’s operating andmaintenance instructions. 3. Discuss proper maintenance with your dealer. 4. Check engine oil. 5. Check fuel cap to be sure it is in place. 6. Be sure par...

23 OPERATION INSTRUCTIONS TESTING OF SAFETY INTERLOCK SYSTEMS: Do not operate mower if safety switches are not operating properly. 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 T...

24 OPERATION INSTRUCTIONS SIDE DISCHARGE OF THE CLIPPINGS: In order to achieve optimum performance when side discharging thegrass 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 properlyi...

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 leverin the top or second notch. “Initially” overlap cutting swathsinstead of a full swath with each pass. Some applicationsmay require a ...

26 STARTING INSTRUCTIONS (engine has been operated): 1. Move throttle control to 1/4to 1/2 setting. 2. Insert ignition key and turn to“start” position. When enginestarts, release ignition key.Key will return to “run” position. 3. Move throttle control to“fast” position. Note: Model 5023 may require ...

28 OPERATION INSTRUCTIONS MOWING WITH A MULCHING ATTACHMENT: Mulching or recycling the grass clippings requires a totally differentmowing approach than would be normal when side discharging orbagging the grass. There may be instances or conditions where it isnot possible to hide all of the recycled ...

29 OPERATION INSTRUCTIONS MOWING WITH A MULCHING ATTACHMENT (continued): 6. Keep the Underside Of The Mower Deck Clean. Remove all grass and dirt build-up from theunderside of the pan, the baffles and deflectorsafter each use. 7. Alternate mower direction. This will evenlydisperse the mulched grass ...

30 OPERATION INSTRUCTIONS MOWING WITH A GRASS CATCHER ATTACHMENT: In order to achieve optimum performance when mowing with a grasscatching attachment, please read and follow the tips listed below. 1. Set engine speed control to the wide open orfull setting. Allow engine, mower deck andblower to reac...

31 OPERATION INSTRUCTIONS MOWING WITH A GRASS CATCHER ATTACHMENT (continued): 7. Operate the mower at a slower ground speed thanwhen mowing without a grass catching attachment. 8. Some mowing applications/use of grass catchersmay require that an optional weight box be fitted tothe mower to counter t...

33 CARE AND MAINTENANCE CAUTION CAUTION CAUTION CAUTION CAUTION Bef Bef Bef Bef Before perf ore perf ore perf ore perf ore perfo r o r o r o r o rming an ming an ming an ming an ming any maintenance y maintenance y maintenance y maintenance y maintenance, tur , tur , tur , tur , turn off engine n of...

35 CARE AND MAINTENANCE CUTTER BLADE MAINTENANCE: CAUTION Stop engine and remove ignition key for safety.Wear heavy, thick gloves when holding ontocutter 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...

36 CARE AND MAINTENANCE BELTS: Check belts every 50 hours. Replace any belts found to be inpoor 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 heldin proper tension by springs which push the deck assemblyforward...

38 CARE AND MAINTENANCE CHANGING THE ENGINE OIL: 1. The “Dapco” oil drain valve is located on the leftside of the engine crankcase. 2. Place a suitable container under the drain valve.The fitting of a short piece of hose will help directthe oil. 3. To drain, turn hex head valve stem counter--clockwi...

39 CARE AND MAINTENANCE OIL FILL: 1. Drain oil. 2. Clean any spilled oil from engine and chassis. 3. Refill engine with type, and quantity of oilrecommended by the engine manufacturer inengine literature. OIL FILTERS: 1. Replace filter each time the oil is changed. 2. These filters can be obtained f...

40 HYDROSTATIC TRANSMISSION OIL & FILTER SERVICE: If transmission is to be serviced, proper airpurging procedures must be followed, ordamage will occur. 1. Remove oil filter from chassis allowingoil to drain into container. Cleanimpurities from inside of reservoir,if necessary. 2. Fill new filte...

41 CARE AND MAINTENANCE HYDROSTATIC TRANSMISSION OIL & FILTER SERVICE (continued): 5. Depress by-pass valve on both hydros. 6. Start engine and move throttle tomid-range setting. 7. Release parking brake. 8. Dirty oil, filled with air bubbles, willstart to drain from oil return hosesinto contain...

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 hours2. Every 250 hours or once a year thereafter. OIL REQUIREMENTS:Any high quality engine oil with an API classif...

43 CARE AND MAINTENANCE ELECTRICAL SYSTEMS: Keep all connections clean and tight. CLEANING THE MOWER: 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 theydry and cause corrosion. SERIAL NUMBERS: The...

44 CARE AND MAINTENANCE MOWER DECK LEVELING PROCEDURE: There are a total of (4) threaded adjusters which willcontrol the attitude or pitch of the mower deck. Theadjusters have locknuts on the bottom which can beturned up or down to raise or lower the front and rearof the mower deck. Deck should be l...

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. At this time,...

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 b...

49 CARE AND MAINTENANCE REAR WHEELS: The rear wheels of all 5000 Series models are of an“offset” center design to allow “reversed” installationfor using snow chains or to gain increased stabilitywhen mowing on sloped ground. Slopes are a major factor related to loss-of-control andtip-over accidents,...

51 CARE AND MAINTENANCE NEUTRAL ADJUSTMENT(continued): 4. Engage parking brake and lower the body. Release parking brake and swing control levers in. Ifwheel 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....

52 CARE AND MAINTENANCE PROCEDURE FOR ELECTRIC CLUTCH ADJUSTMENT: Electric clutches require periodic Air Gap adjustments for extendedlife. Listed below is both an Air Gap adjustment procedure and anOhms test to check for a faulty coil within the clutch. No replacementparts are available to repair a ...

53 CARE AND MAINTENANCE PROCEDURE FOR ELECTRIC CLUTCH ADJUSTMENT (CONTINUED): 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 2.5 to 4.0 OHMS. 4. If the ...

54 CARE AND MAINTENANCE FORWARD TRAVEL SPEED ADJUSTMENT: 1. Drive machine on a smooth surface with bothlevers in top speed position. 2. If one side drives slightly faster than the other,adjust forward speed bolt in to contact stopsooner. If levers are now uneven at top speed,loosen control lever mou...

55 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 6111Serpentine - P/N 1300Engine to T-Box - P/N 7253T-Box to Hydros - P/N 1765Grass Blower Belt - P/N 4983 60” Deck Blades: P/N 9445 (Hi-Lift) Belts: Engine to Mower Deck ...

56 1 . ENGINE WON’T TURN OVER Mower blades engaged- - - - - - - - - - - - - - - - - - - - - - -disengage bladesDrive not in neutral - - - - - - -move control levers to neutral “OUT”Circuit breaker trips- - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - reset breakerDead battery- - - - - ...

57 TROUBLESHOOTING 6. ENGINE RUNS BUT MOWER WON’T MOVE FORWARD Drive belt broken or slipping- - - - - - - - - - - - - - - - - - - - replace drive beltTransmission oil low- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - -add oilTransmission locks in free-wheel position- - - - lo...

ZTR®Mowers ZTR®Mowers ZTR®Mowers ZTR®Mowers ZTR®Mowers Dixon® and ZTR® are registered trademarks of Dixon Industries, Inc. DIXON INDUSTRIES, INC.a BLOUNT International Inc. Co.P.O. Box 1569Coffeyville, Ks 67337-0945620-251-2000 5000 Series 5020 & 5023 Part No. 13089-0601 W W W W WARNING: ARNING:...