Dixon ZTR 5020 User manual

ZTR®
OPERATOR’S MANUAL
5000 SERIES
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.

3
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

4
RIDING LAWN MOWERS,
IFIMPROPERLY OPERATED,
CAN CAUSE SERIOUS INJURY OR DEATH.
The most common causes of injury to the operator or bystander...
...readandunderstandthismanualtopreventinjuries.
BLADECONTACT
TIP OVER
RUNOVER
BACK OVER
SAFETY

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 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.
Follow recommended safety precautions
and safe operating practices.
SAFETY

6
Failure to observe the following safety
instructions could result in serious injury or death.
GENERALOPERATION:
•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.
•NEVERcarrypassengers.
•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. Alwaysturn off
blades, set parking brake, stop engine and remove key before
dismounting.
SAFETY

7
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.
WARNING:
The engine exhaust from this product contains chemicals known to the
State of California to cause cancer, birth defects or other reproductive
harm.
SAFETY

8
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.
DONOT
• 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.
SAFETY

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 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.

10
SERVICE:
• Useextracareinhandling gasoline andother fuels. They are
flammableandvaporsareexplosive.
Useonlyanapprovedcontainer.
Neverremovefuelcaporadd fuel with enginerunning.
Allowenginetocoolbeforerefueling.
Donotsmoke while refueling.
Neverrefuelthemower indoors.
Neverstorethemowerorfuelcontainer inside a building
where there is an open flame.
Iffuelis spilled onclothing,changeclothingimmediately.
Topreventfireand explosion causedbystatic electricity:
Neverfill containers inside a vehicle or on a truck
or trailer bed with a plastic liner. Always place
containersonthegroundawayfromyourvehicle
beforefilling.
Whenpractical,removefuel-poweredequipment
from the truck or trailer and refuel it on the
ground. If this is not possible, then refuel such
equipmentonatrailerwithaportablecontainer,
ratherthanfromafueldispensernozzle.
If a fuel dispenser nozzle must be used, keep the
nozzle in contact with the rim of the fuel tank or
containeropeningatalltimesuntilfuelingis
complete. Do not use a nozzle lock-open device.
SAFETY

11
SERVICE(continued):
• Never run a mower inside a closed area. The exhaust fumes are
toxic.
• Keepnuts and boltstight, especiallyblade attachmentbolts, and
keepequipmentingood condition.
• Nevertamper withsafety devices. Checktheir properoperation
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,
ifnecessary,before restarting.
• Nevermakeadjustmentsorrepairswiththeenginerunning
unlessotherwisespecified.
• Grass catcher components are subject to wear, damage and
deterioration,whichcouldexposemovingpartsorallowobjects
tobe thrown. Frequentlycheck components and replace with
originalequipmentparts,whennecessary.
• Mower blades are sharp and can cut. Wrap the blade(s) or wear
gloves,anduseextracaution when servicing them.
• Batteriescontainsulfuric acid. To preventburnsavoid contact
with skin, eyes and clothing. To prevent a fire or explosion keep
sparks and open flames away from battery.
• Beforedisconnectingthenegative(-)groundcable,makesure all
switches are OFF.
SAFETY

12
DIXON INDUSTRIES, INC.
aBLOUNTcompany
AirportIndustrialPark
P.O.Box1569
Coffeyville,Ks67337- 0945
620-251-2000
Fax[phone]
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
ANDWORKMANSHIPANDPROVIDESFORREPLACEMENTORREPAIR
OFPARTSINCLUDING LABORCOSTS. THISWARRANTYISSUBJECT
TOTHEFOLLOWING CONDITIONSANDLIMITATIONS:
1. Warranty applies only to original retail purchaser of new & unused mowers and accessories.
2. AllDixonwarrantymustbeaccomplishedbyauthorizedDixondealersandinaccordancewithDixon
warranty policy and allowances. All warranty claims must be approved by Dixon Industries, Inc.
3. Batterywarranty: Limited to 90days from date of purchase.
4. AccessoriesWarranty(Grass Catchers,Snow Blades,Covers,etc.): Limited to90 days fromdate of
purchase.
5. Warrantydoes notapply todamage in transitor incidentsof misuse,negligence, accidents, or
alteration. The use of parts or components other than those supplied by Dixon Industries,
Inc. VOIDS ALL WARRANTY.
6. Thefollowing itemsarenot coveredby thiswarranty policy:
a. Pick upand deliverycharges fortransportation ofmowerto andfrom anauthorized Dixon
dealer’splace of business.
b. Routine maintenanceor adjustments.
c. Belts/cutting blades/Hydro-Gear filters.
d. Engines - Allengines used onDixon ZTRmowers are warrantedby the individualengine
manufacturer.
e. Anycosts or expenseof providingsubstitute equipmentwhilerepair workis being
performed on a warranted mower.
7. Thereisno otherexpresswarranty. Implied warranties,including thoseofmerchantability andfitness
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’sSignature Dealer’sSignature

13
SPECIFICATIONS
Model ZTR 5020
CHASSIS: 11GA - rectangular tube
BODY: Two piece-made of rotational molded polyethylene. Front
bodycontainsaccesspanelsforbatteryservice&engine
to mower deck belt removal. Rear body tilts up to allow
serviceontheentiredrivesystem.
SEAT: Designedforoperatorcomfortby use ofhigh-density
closed cell foam padded back rest and arm rests,
upholsteredwith CorduraTM water-repellent fabric. Seat
isadjustable fore andaft.
MOWERDECK: Two decks are available. The 60” is made of stamped
steel. The50” is made of 11 GA fabricatedwelded
constructionwithexternalreinforcementribs. Three
bladescombine for eithera 50”or 60” cutwidth. Cut
heightapproximately1.5”to4.5”via7positionlifthandle.
BLADEDRIVE: Electricclutch
DRIVESYSTEM: Each rear wheel isindependently driven by aHydroGear
BDU-10LSeries70hydrostatictransmission. Thehydrostatic
transmissionspowerafullyenclosedHydroGeargearbox.
ENGINE: 20HPBriggs&StrattonELS,overheadvalves,replaceable
oilfilter,fullpressurelubesystem,dualelementaircleaner,
integral fuel pump.
STARTINGSYSTEM: Electricbykeyswitchoperationwithsafetyinterlockson
parking brake and blade drive clutch.
TIRES: Front 11 X 4-5 ribbed tread
Rear 20X10-8Multi-Trac
RECOMMENDED Front 16 - 21 lbs.
TIREPRESSURE: Rear 8 - 14 lbs.
CAPACITIES: Fuel - 4.8 gallons total (dual tanks)
Oiltank-3quartwithin-line40micronfilter
Engine-2qts.SAE30(withfilter)
DIMENSIONS: Width 60”(50”Deck),73”(60”Deck)
Height 45”
Length 72:
Weight 668lbs,(50”Deck,685lbs(60”Deck)
Additionalinformation providedin serviceinstructions underthe individualcomponent.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

14
SPECIFICATIONS
Model ZTR 5023
CHASSIS: 11GA -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.
MOWERDECK: 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.
BLADEDRIVE: Electric clutch
DRIVESYSTEM: 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: 23HPKohlerCommand,4-Cycle,V-Configuration,OverheadValve,
Air-Cooled,Gasoline,VerticalShaft,AluminumHead,andCrankcase
with Cast Iron Liners, Full Pressure Lubrication/Full Flow Filter,
Pulse-type Fuel Pump, Fixed Jet Carburetor w/Smart-Choke,
ElectronicIgnition,In-LineFuelFilter,DualElementAirCleaner.
STARTINGSYSTEM: Electric by key switch operation with safety interlocks on parking
brake and blade drive clutch.
TIRES: Front 11X 4-5 RibbedTread
Rear 20 X 10-8Multi Trac
RECOMMENDED Front 16-21lbs.
TIREPRESSURE: Rear 8 - 14 lbs.
CAPACITIES: Fuel-4.8gallonstotal(dualtanks)
Hydrostat oil tank - 3 quart with in-line 40 micron filter
Engine- 2qts. SAE 10W30(with filter)
DIMENSIONS: Width 60"(50"Deck),72"(60"Deck)
Height 45"
Length 72"
Weight 680lbs.(50"Deck),685lbs.(60"Deck)
Additional information provided in service instructions under the individual component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTIFICATION

15
SEAT ADJUSTMENT INSTRUCTIONS
5000 Series Models
1. Grasp seat slide adjuster and move
it intoadjustment position.
2. Slide seat forward or backward.
3. Release seat slide adjuster.

16
CONTROLS
CONTROLLEVERS
Note: For access to the seat, move control levers to neutral position and
swing them outward.
TOGOFORWARD:
•Fromneutralposition,gently push bothcontrolleversforward.
•To increase speed, move levers further forward.
TOGOBACKWARD:
•From neutral position, gently pull both control levers toward you.
TURNING:
•Turning is controlled by moving one control lever slightly forward or
rearward of the other.
•To turn left, move left lever rearward of the right lever.
•To turn right, move right lever rearward of the left lever.
•To turn on mower’s own axis (zero turning radius), stop and move one
lever to reverse position and the other to forward position.
BRAKING:
•To brake mower, move both levers in direction opposite of travel.
LEFT TURN OPPOSITE
Note: The pressure required to operate the mower is very light.

17
CONTROLS
CHOKE CONTROL LEVER:
•Located on control panel to operator’s right.
•Used to start a cold engine.
THROTTLE CONTROL LEVER:
•Locatedon controlpanel to operator’sright.
•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.

18
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 Engageparkingbrakebefore
startingengine.
TO SET PARKING BRAKE:
The hand operated brake is located at
thelefthand side of the mower.
Toengage brake,pulllever up(to the
rear).
Toreleasebrake,moveleverforward
(down).
Note: Always set parking brake
beforedismounting. Release
parkingbrakebeforemoving
mower.
HYDRO GEAR SYSTEM:
•Allows the mower to turn on its own
axis (zeroturning radius).
•Each lever controls one side of the
mower.
•Note: Thepressure requiredto operate
the mower is very light.

19
CONTROLS
MOWER DECK CUT HEIGHT LIFT LEVER:
•Located to the right and front of
operator.
•Controls the cutting height.
•Seven positions of adjustment.
•Depresstriggerandmoveleverforward
to lower deck.
•Depress trigger and pull lever back to
raise deck.
NOTE: Always use high position for transport.
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.
•Ifcircuit breakertrips, pushbutton
to reset.
•If this condition repeats, consult
dealer forinspection andrepair.

20
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
plungersreturntotheirnormalpositions.
NOTE: Beforepushing ortowingtractor, transmission
must be unlocked, and parking brake released.
Thetractor shouldnever bepulledatmorethan
2 miles per hour or for any appreciable distance.