Dixon ZTR 5023, ZTR 5425 User Manual

2000 Operator's Manual

5000

SERIES

1Page

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 in this operator's manual applies to all Dixon® ZTR® 5000 Series Commercial Mowers. Your Dixon dealer will gladly answer any questions.

See your dealer for warranty service, parts and repairs.

Page 2

DIXON INDUSTRIES, INC. A BLOUNT International Inc. Co. PO BOX 1569 COFFEYVILLE KS 67337 0945 316 251 2000

INDEX

SAFETY..........................................................Pages 2 - 7

WARRANTY POLICY .....................................Page 8

SPECIFICATIONS ..........................................Pages 9 - 11

SEAT ADJUSTMENT.....................................Page 12

CONTROLS....................................................Pages 13 - 16

OPERATION INSTRUCTIONS.......................Pages 17 - 23

CARE AND MAINTENANCE ..........................Pages 24 - 39

STANDARD SERVICE PARTS LIST .............Pages 40 - 41

TROUBLESHOOTING ...................................Pages 42 - 44

5000 Series Part No. 1858-0599

3Page

SAFETY

RIDING LAWNMOWERS, IF IMPROPERLY OPERATED,

CAN CAUSE SERIOUS INJURY OR DEATH

The most common causes of injury to the operator or bystander...

BLADE CONTACT

RUN-OVER

...read and understand this manual to prevent injuries.

TIP-OVER

BACK-OVER

Page 4

SAFETY

SAFETY SYMBOLS

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.

Warning

indicates a potentially hazardous situation which, if not avoided, could result in death

or serious injury.

Caution

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.

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SAFETY

This cutting mower is capable of amputating hands & feet, and throwing objects.

Failure to observe the following safety instructions could result in

serious injury or death.

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 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.

• 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 crossing roadways.

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

W ARNING:

Page 6

The engine exhaust from this product contains chemicals known to the

State of California to cause cancer, birth defects or other reproductive harm.

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.

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.

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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.

12 VOLT UTILITY OUTLET

A utility outlet is provided for use with 12 volt DC attachments. It is located just ahead of the instrument panel.

Output is limited to 5 amps.

We do not recommend the use of sound equipment (such as CD players with earphones) that could interfere with the operators hearing. The operator may not hear impending hazards and could be distracted from the safe operation of the mower.

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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 building where there is an open flame.

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 gas-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 gasoline dispenser nozzle.

If a gasoline 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.

• 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.

• 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.

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DIXON LIMITED W ARRANTY POLICY -- EST ATE 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 as any use other than at owners primary place of residence. are warranted for a period of two (2) years from date of purchase. 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 and 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, Tine Rakes, 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.

Home Owner Applications: Dixon Estate Models used primarily at the owner’s place of residence

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 / HydroGear Filters. (d) Engines -- All engines used on Dixon ZTR mowers are warranted by each 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.

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)

(Address)

(Dealership)

(Address)

Page 10

(Dealer's Signature) (Owner's Signature)

SEE DEALER FOR DETAILS

SPECIFICATIONS

Model ZTR 5020

CHASSIS: 11 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 closed cell foam

padded back rest and arm rests, upholstered with Cordura repellent fabric. Seat is adjustable fore and aft.

MOWER DECK: 2 Decks are available. 60" is made of stamped steel. 50" is made of

11 GA fabricated welded construction with external reinforcement ribs. 3 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, in

turn, power a fully enclosed HydroGear gearbox. ENGINE: 20HP Briggs & Stratton Intek, 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 X 5 smooth profile

Rear 20 X 10 X 8 Multi Trac RECOMMENDED Front 16 - 21 lbs.

TIRE PRESSURE: Rear 8 - 14 lbs.

water-

CAPACITIES: Fuel - 4.8 gallons total (dual tanks)

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

Hydrostat oil recommendation, refer to page 36

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) NOTE: Additional information provided in service instructions under the

individual component.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

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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 Cordura fabric. Seat is adjustable fore and aft.

MOWER DECK: 2 Decks are available. 60" is made of stamped steel. 50" is made of

11 GA fabricated welded construction with external reinforcement ribs. 3 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, 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 X 5 ribbed tread

Re a r 20 X 10 X 8 Multi Trac

water-repellent

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

Hydrostat oil recommendation, refer to page 36

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) NOTE:

Additional information provided in service instructions under the individual

component.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

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SPECIFICATIONS

Model ZTR 5425

CHASSIS: 11 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 closed cell foam

padded back rest and arm rests, upholstered with Cordura repellent fabric. Seat is adjustable fore and aft.

MOWER DECK: 13 ga stamped steel construction. 3 blades combine for a 42" 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: 17HP Briggs & Stratton Intek, 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 X 5 smooth profile

Rear 18 X 9.5 X 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

Hydrostat oil recommendation, refer to page 36

Engine - 2 qts. SAE 30 (with filter)

water-

DIMENSIONS: Width 54"

Height 45"

Length 72"

Weight 615 lbs NOTE: Additional information provided in service instructions under the

individual component.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

13Page

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 14

CONTROLS

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