Dixon ZTR 5023 - Manuals

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. Warn...

Page 8 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 a...

Page 10 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...

11 Page SPECIFICATIONS Model ZTR 5020 CHASSIS: 11 GA - rectangular tube BODY: Two piece - made of rotational molded polyethylene. Front bodycontains access panels for battery service and engine to mower deckbelt removal. Rear body tilts up to allow service on the entire drivesystem. SEAT: Designed f...

Page 14 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 16 CONTROLS PARKING BRAKE: CAUTION Engage parking brake before starting engine The parking brake is designed to hold the mower frommoving and is not intended for use in stopping the mower while it is in motion. TO SET PARKING BRAKE: The hand operated parking brake is located atleft hand side of...

17 Page CONTROLS (left turn opposite) TO GO FORWARD: From neutral position, gently push both drive levers forward. To increase speed, move levers farther forward. TO GO BACKWARD: From neutral position, gently pull both drive levers toward you. TURNING: Turning is controlled by moving one drive lever...

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 break...

19 Page OPERATION INSTRUCTIONS Safe and successful operation will depend upon the operator having the correctknowledge of all controls used on the mower and making good judgements about theterrain to be mowed. NEVER allow anyone to operate the mower without complete knowledge of all controls and the...

Page 20 OPERATION 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 positionb) Engage blade drive switchc) Turn ignition switch to STAR...

21 Page OPERATION INSTRUCTIONS 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" positio...

Page 22 OPERATION INSTRUCTIONS MOWING WITH A MULCHING ATTACHMENT : Mulching or recycling the grass clippings requires a totally different mowing approachthan would be normal when side discharging or bagging the grass. There may beinstances or conditions where it is not possible to hide all of the re...

23 Page OPERATION INSTRUCTIONS MOWING WITH A GRASS CATCHER ATTACHMENT: In order to achieve optimum performance when mowing with a grass catching attachment,please read and follow the tips listed below: 1. Set engine speed control to the wide open or full setting. 2. Do Not Attempt To Cut Grass When ...

Page 24 OPERATION 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 slight...

25 Page 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 onuneven ground. Height: Normal height settings as installed at the factory allows each r...

Page 26 CARE AND MAINTENANCE This portion of the owner's manual deals with normal service items which can be performed bythe owner. Please remember that if you are in doubt as to the correct service procedures tobe followed, these and other service situations can be handled by a Dixon ZTR dealer who...

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 ...

Page 28 REARHANGERPIN BELT TENSION ENGINE TO MOWER DECK BELT : 42" and 50" P/N 6111 60" P/N 6938 The engine to mower deck drive belts are automatically held in propertension by springs which push the deck assembly forward and do notrequire any additional adjustment to be made. MOWER DECK...

29 Page 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 c...

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 he...

Page 32 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 handleinto the lowest cut position. Belt can now be removed frommower deck pulley. 3. Slide deck from beneath ch...

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 adjustershave lock nuts on the bottom which can be turned up or down to raise or lower the front and rear of the mowerdeck. Deck sho...

35 Page CARE AND MAINTENANCE NOTE: Cable must have the recommended 1-1/2 to 2 inches of free play with parkingbrake released or drive belt may slip, causing loss of power. ADJUST HERE FOR PROPER FREE PLAY OF CABLE WITH BRAKE LEVER OFF PARKING BRAKE CABLE ADJUSTMENT: Make necessary adjustments to the...

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 RODADJUST IN STEP C 5540 CONTROL TUBE 4. Engage parking brake and lower the body. Release parking brake and swing control levers in. If whee...

37 Page CARE AND MAINTENANCE 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 c...

Page 38 CARE AND MAINTENANCE PROCEDURE FOR ELECTRIC CLUTCH ADJUSTMENT Electric clutches require periodic Air Gap adjustments for extended life. Listed below isboth an Air Gap adjustment procedure and an Ohms test to check for a faulty coil within theclutch. No replacement parts are available to repa...

39 Page CARE AND MAINTENANCE HYDROSTATIC TRANSMISSION OIL AND FILTER SERVICE SERVICE INTERVALS: 1. Initial oil and filter service - 50 hours.2. Every 250 hours thereafter. OIL REQUIREMENTS: Any high quality engine oil with an API classificationof SG/CD is recommended. RECOMMENDED OIL WEIGHT: Normal ...

Page 40 CARE AND MAINTENANCE HYDROSTATIC TRANSMISSION OIL & FILTER SERVICE If transmission is to be serviced, proper air purging procedures must be followed, ordamage will occur. Proceed as follows: 1. Remove oil filter from chassis, allowing oil to drain into container. Clean impurities from in...

41 Page CARE AND MAINTENANCE WHEELS AND TIRES: Correct tire pressure is important for correct operation ofmower. 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 SYS...

Page 42 STANDARD SERVICE PARTS LIST 42" DECK BLADES: Lo Lift P/N 6236 Standard Hi-Lift P/N 8688 B E LT S : Engine to Mower Deck P/N 6111 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-Lift P/N 9443 Standard Hi-Lift P/...

43 Page STANDARD SERVICE PARTS LIST KOHLER AND BRIGGS & STRATTON AIR AND OIL FILTER PART NUMBERS: Refer to engine manufacturers manual for recommendations regarding frequency ofservice required for engine oil changes and air filter maintenance. Protect your engine investment, use only original e...

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 req...

49 Page Dixon ® and ZTR ® are registered trademarks of Dixon Industries, Inc. 5000Series5020,5023&5425Part No. 1858-0599 DIXON INDUSTRIES, INC.A BLOUNT INTERNATIONAL INC. CO.PO BOX 1569COFFEYVILLE KS 67337 0945316 251 2000 The engine exhaust from this product contains chemicals known to the Stat...