Dixon 13089-0601 User Manual

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OPERATOR’S MANUAL

5000 SERIES

ZTR®

2002

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.

The information contained in this manual applies to all Dixon® ZTR® 5000 Series Mowers. Your Dixon dealer will gladly answer any questions.

See your dealer for warranty service, parts and repairs.

INDEX

Page

Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-14

Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . . . . . . . .15

Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-20

Operation Instructions. . . . . . . . . . . . . . . . . . . 21-32

Care & Maintenance. . . . . . . . . . . . . . . . . . . . . .33-54

Standard Service Parts List. . . . . . . . . . . . . . . . . . . .55

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 56-57

5000 Series

Part No. 13089-0601

3

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.

4

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 hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION (highlighted in yellow) 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.

5

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.

•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.

6

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.

•Use extra care when loading or unloading the mower into a trailer or truck. Do not ride the mower when loading and unloading.

•Always wear safety goggles or safety glasses with side shields when operating mower.

•Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mower-related injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury.

•Follow the manufacturer’s recommendation for wheel weights and counterweights.

Maintain or replace safety & instruction labels as needed.

The engine exhaust from this product contains chemicals known to the WARNING: State of California to cause cancer, birth defects or other reproductive

harm.

7

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. Tires may lose traction on slopes even though the brakes are functioning properly.

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.

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 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.

9

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.

Never refuel the mower indoors.

Never store the mower or fuel container inside a building where there is an open flame.

If fuel is spilled on clothing, change clothing immediately.

To prevent fire and explosion caused by static electricity:

Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling.

When practical, remove fuel-powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment on a trailer with a portable container, rather than from a fuel dispenser nozzle.

If a fuel dispenser nozzle must be used, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device.

10

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.

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 unless otherwise specified.

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.

11

DIXON INDUSTRIES, INC. a BLOUNT company Airport Industrial Park

P.O. Box 1569

Coffeyville, Ks 673370945

620-251-2000

Fax 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)years from date of purchase. Commercial Application: Dixon mowers used for commercial application are warranted for one (1) year from the date of purchase or 400 hours whichever comes first.

Commercial use is specified as use other than, or in addition to, mowing at owner’s primary place of residence.

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 & 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.Battery warranty: Limited to 90 days from date of purchase.

4.Accessories Warranty (Grass Catchers, Snow Blades, Covers, etc.): Limited to 90 days from date of purchase.

5.Warranty does not apply to damage in transit or incidents of misuse, negligence, accidents, or alteration. The use of parts 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.Routine maintenance or adjustments.

c.Belts/cutting blades/Hydro-Gear filters.

d.Engines - All engines used on Dixon ZTR mowers are warranted by the individual engine manufacturer.

e.Any costs or expense of providing substitute equipment while repair work is being performed on a warranted mower.

7.There is no other express warranty. Implied warranties, including those of merchantability and fitness for a particular 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.

Blue/Customer

Yellow/Dealer

White/Dixon Ind.

WARRANTY VALIDATION: At the time of sale, selling dealer must review each portion of this warranty document, complete the information section below, secure customer’s signature and send copy to Dixon Industries, Inc.

DATE OF PURCHASE____________________MODEL___________________S/N_______________

_____________________________________

______________________________________

Owner’s Name

Dealership

_____________________________________

______________________________________

Address

Address

______________________________________

_______________________________________

_____________________________

______________________________

Owner’s Signature

Dealer’s Signature

12

 

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.

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:

Two decks are available. The 60” is made of stamped

 

steel. The 50” is made of 11 GA fabricated welded

 

construction with external reinforcement ribs. Three

 

blades combine for either a 50” or 60” cut width. Cut

 

height approximately 1.5” to 4.5” via 7 position lift handle.

BLADE DRIVE:

Electric clutch

DRIVE SYSTEM:

Each rear wheel is independently driven by a HydroGear

 

BDU-10L Series 70 hydrostatic transmission. The hydrostatic

 

transmissions power a fully enclosed HydroGear gearbox.

ENGINE:

20HP Briggs & Stratton ELS, overhead valves, replaceable

 

oil filter, full pressure lube system, dual element air cleaner,

 

integral fuel pump.

STARTING SYSTEM:

Electric by key switch operation with safety interlocks on

 

parking brake and blade drive clutch.

TIRES:

Front

11 X 4-5 ribbed tread

 

Rear

20 X 10-8 Multi-Trac

RECOMMENDED

Front

16 - 21 lbs.

TIRE PRESSURE:

Rear

8 - 14 lbs.

CAPACITIES:

Fuel - 4.8 gallons total (dual tanks)

 

Oil tank - 3 quart with in-line 40 micron filter

 

Engine - 2 qts. SAE 30 (with filter)

DIMENSIONS:

Width

60” (50” Deck), 73” (60” Deck)

 

Height

45”

 

Length

72:

 

Weight

668 lbs, (50” Deck, 685 lbs (60” Deck)

Additional information provided in service instructions under the individual component.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

13

 

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.

 

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:

Two decks are available. The 60" is made of stamped steel. The

 

50" is made of 11 GA fabricated welded construction with external

 

reinforcement ribs. Three blades combine for a 50" or 60" cut

 

width. Cut height approximately 1.5" to 4.5" via 7 position lift

 

handle.

 

BLADE DRIVE:

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:

23HP Kohler Command, 4-Cycle, V-Configuration, Overhead Valve,

 

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 Carburetor w/Smart-Choke,

 

Electronic Ignition, In-Line Fuel Filter, Dual Element Air Cleaner.

STARTING SYSTEM:

Electric by key switch operation with safety interlocks on parking

 

brake and blade drive clutch.

TIRES:

Front

11 X 4-5 Ribbed Tread

 

Rear

20 X 10-8 Multi Trac

RECOMMENDED

Front

16 - 21 lbs.

TIRE PRESSURE:

Rear

8 - 14 lbs.

CAPACITIES:

Fuel - 4.8 gallons total (dual tanks)

 

Hydrostat oil tank - 3 quart with in-line 40 micron filter

 

Engine - 2 qts. SAE 10W30 (with filter)

DIMENSIONS:

Width

60"(50" Deck), 72"(60" Deck)

 

Height

45"

 

Length

72"

 

Weight

680 lbs.(50" Deck), 685 lbs.(60" Deck)

Additional information provided in service instructions under the individual component.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTIFICATION

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.

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