ZTR®
OPERATOR’S MANUAL
2003
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INDEX
Page
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-18
Operation Instructions. . . . . . . . . . . . . . . . . . . 19-26
Care & Maintenance. . . . . . . . . . . . . . . . . . . . . .27-38
Standard Service Parts List. . . . . . . . . . . . . . . . . . . .39
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . .40-41
8000 Series (Gas)
Part No. 13637-xxxx
3
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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
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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
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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. Alwaysturn off
blades, set parking brake, stop engine and remove key before
dismounting.
6
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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.
WARNING:
The engine exhaust from this product contains chemicals known to the State of
California to cause cancer, birth defects or other reproductive harm.
7
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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
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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.
9
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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 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
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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
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DIXON INDUSTRIES, INC.
a BLOUNT company
Airport Industrial Park
P.O. Box 1569
Coffeyville, Ks 67337- 0945
620-251-2000
Fax 620-251-4117
DIXON LIMITED WARRANTY POLICY - COMMERCIAL MODELS
8000 Series
WARRANTY: Home Owner Application: This Dixon Warranty term is for a period of three (3)
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 750 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 & 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.
c.
d.
Routine maintenance or adjustments.
Belts/cutting blades/hydrostatic filters.
Engines - All engines used on Dixon ZTR mowers are warranted by the individual engine
manufacturer.
Any costs or expense of providing substitute equipment while repair work is being
performed on a warranted mower.
e.
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 &
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
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SPECIFICATIONS
8000 Series (Gas Version)
CHASSIS:
SEAT:
11 GA - rectangular tube, 7 GA reinforcement
Designed for operator comfort with padded back & arm
rests. Seat is adjustable fore & aft. Seat back tilts. Mounted
on operator suspension system with damper.
MOWERDECK:
2 decks are available. Both decks are made of 10 GA
fabricated welded construction with 1/4 " reinforcement
plate. 3bladescombineforeithera60"or72"cutwidth. Deep
deckwithdischargetunnel. Cutheightapproximately1.5"to
6" via 10 position lift handle.
BLADEDRIVE:
"V" Belt with Electric clutch
DRIVE SYSTEM:
EachrearwheelisindependentlydrivenbyaHydroGearBDP-
10A pump and White CE wheel motor.
ENGINE:
25HPKohlerCommand, 4-Cycle, V-Configuration, Overhead
Valve,Air-Cooled,Gasoline,HorizontalShaft,AluminumHead
and Crankcase with Cast Iron Liners, Full Pressure
Lubrication/Full Flow Filter, Pulse-type Fuel Pump, Fixed Jet
Carburetor,ElectronicIgnition,In-LineFuelFilter,DualElement
AirCleaner.
STARTINGSYSTEM:
TIRES:
Electric by key switch operation with safety interlocks on
parking brake, blade drive clutch and control levers.
Front
Rear
13-6.5x6
23-10.5x12
RECOMMENDED
TIREPRESSURE:
Front
Rear
16-20lbs.
8-14lbs.
CAPACITIES:
Fuel - 11 gallons (approx)
Hydrostat oil system - 4 quart with in-line 40 micron filter
Hydrostat oil recommendation - SAE 20W50 motor oil
Engine - 2 quart. SAE 10W30 motor oil
DIMENSIONS:
Width
Height
Length
Weight
73.5"(60"Deck),85.5"(72"Deck)
54"
87"
1020 lbs.(60" Deck), 1054 lbs.(72" Deck)
NOTE: Additional information provided in service instructions under the individual component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.
13
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CONTROLS
CONTROL LEVERS
Note: For access to the seat, move control levers to neutral position and
swing 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 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.
14
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CONTROLS
PARKING BRAKE:
A parking brake is located to the left of the seat.
The engine will kill if control levers are not in the outboard position
when the parking brake is engaged.
To engage brake: pull up and back
To disengage brake: push forward and down
Note: The parking brake is not intended to be used as a service
brake.
Note: Always set parking brake before dismounting. Release the
parking brake before moving mower.
Note: Engage parking brake before starting engine.
MOWER DECK LIFT:
The mower lift lever is extra long & has an assist spring for easy
operation.
1)
2)
3)
Grasp lever with right hand.
Depress thumb lever to release. Move to desired position.
Release lever to lock into position.
Select cut height & insert pin into first hole below the lift lever. Ten
holes are provided for a down stop so you can easily return from`
transport to desired cut height.
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CONTROLS
SEAT:
Fore & Aft: Move lever, slide seat fore & aft to desired
position, release.
Seat Damper: A shock is located on the left side of
the seat frame. Remove clip on the top and pull plunger
up. Rotate shaft clockwise to make ride stiffer and
counter- clockwise for a softer ride. Reattach to seat
frame with clip.
Attention: Do not completely close off the damper.
Closing off the damper causes it to become stiff making
it difficult to fully extend the damper in order to open the
adjustment. THE PRODUCT IS NOT DAMAGED. To
restore adjustment follow these instructions: Hang the
damper in the vertical position with the rod pointing
down. Attach a load of approximately 15 pounds to the
rod end of the damper. The load will slowly extend the
damper. When fully extended the adjustment pin will be
engaged. Turn rod with the weight still hanging to open
the adjustment.
16
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CONTROLS
MOWER BLADE SWITCH:
To engage blades: pull up on switch
To disengage blades: push down
IGNITION SWITCH:
•Turn to start position to crank engine.
Release when it starts.
•For headlights - rotate switch one
notch counter-clockwise from run.
Note: Remove key when mower is
not in use.
CHOKE CONTROL LEVER:
•Located on the control panel to the
operator’s right.
THROTTLE CONTROL LEVER:
•Located on control panel to operator’s right.
•Controls engine speed.
•While mowing, throttle control should be set to MAXIMUM or wide
open setting to insure adequate cooling of the engine and to
maintain mower deck blade speed.
CIRCUIT BREAKER:
•If circuit breaker pops up, it disconnects the power. Wait 2 minutes
and push to reset.
•If it pops up again, there is a short circuit. Stop and find fault or
contact your dealer.
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CONTROLS
18
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OPERATION INSTRUCTIONS
The safe and successful operation of the Model ZTR 8000 Series
will depend upon the operator having the correct knowledge of all
controls used on the mower and making good judgements about
the terrain to be mowed.
NEVER allow anyone to operate the mower without complete
knowledge of all controls and their functions.
During initial operation, “learning to drive”, set throttle at slow
speed.
BEFORE OPERATING MOWER:
1.
Read and observe all safety instructions on your
mower and in the manual.
2.
Read engine manufacturer’s operating and
maintenance instructions.
3.
4.
5.
6.
7.
Check engine oil.
Check fuel cap to be sure it is in place.
Be sure parking brake is on.
Mower blade drive is off.
Know how to stop engine. (Turn key to off
position).
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OPERATION INSTRUCTIONS
TESTING OF SAFETY INTERLOCK SYSTEMS:
Do not operate mower if safety switches are not operating properly.
Your Zero Turning Radius Mower is equipped with control interlocks
for your safety.
1.
2.
3.
4.
The engine will not start if the mower blades are
engaged.
The engine will not start unless the steering control
levers are neutral “OUT” position.
The engine will stop if the mower blade clutch is
engaged and the operator leaves the driver’s seat.
The engine will stop if the park brake is ON and the
steering control levers are moved to the “IN” position.
20
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OPERATION INSTRUCTIONS
INTERLOCK SWITCH TEST
Note: Operator must be seated in normal operating position to
perform these tests.
1.
2.
3.
With engine off, turn mower blade on and attempt to
start engine.
ENGINE SHOULD NOT START.
With engine off, move control levers in and attempt to
start engine.
ENGINE SHOULD NOT START
In a SAFE AREA, away from bystanders, start the
engine, place throttle setting at maximum or full.
Engage the blade drive through the electric clutch
switch. Raise slightly off of seat.
ENGINE SHOULD STOP.
4.
With engine running, set parking brake and move
levers inboard.
ENGINE SHOULD STOP.
If any safety check fails, do not operate the mower until the
system has been checked and repaired by an authorized
Dixon ZTR dealer.
21
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OPERATION INSTRUCTIONS
STARTING INSTRUCTIONS:
1.
Operator must be seated in normal operating position.
2.
3.
4.
5.
6.
Set parking brake.
Move control levers to outboard position.
Assure blade clutch is off.
Push throttle control lever to 1/2 setting.
Push choke control lever forward.
*If engine is warm, turn choke off immediately after
engine starts.
*If engine is cold, slowly move choke to off as the engine
warms up.
7.
8.
Insert Ignition key and turn to start position. When engine
starts, release ignition key. Key will return to “run” position.
Move throttle control lever to the wide open or maximum
setting for actual operation of the mower deck. Engine
must be operated at wide open or maximum setting to
insure adequate lubrication, cooling and cut quality of the
mower deck.
Do not operate the engine in an enclosed area
due to the harmful exhaust gas produced.
CAUTION
STOPPING INSTRUCTIONS:
1.
Turn mower blades off.
2.
3.
4.
Move control levers to outboard position.
Set parking brake.
Move throttle control to slow. Allow engine to run a
short time to cool down then turn ignition key to “OFF”
and remove key.
22
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OPERATION INSTRUCTIONS
MOWING INSTRUCTIONS:
CAUTION Be sure that deflector is properly
installed on the discharge chute.
1.
2.
3.
Start engine and set throttle at full speed.
Set desired cut height.
Release park brake.
CAUTION Check the area to assure there is no
one near.
4.
5.
Engage mower blades.
Move control levers in and operate per the
controlinstructions on Page 14.
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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 lever
in the top or second notch. “Initially” overlap cutting
swaths instead of a full swath with each pass. Some
applications may require a second cutting.
Keep the underside of the mower deck clean.
Maintain sharp blades throughout the cutting season.
As a rule of thumb, never cut off more than 1/3 of the
total grass blade length.
Correct mowing height can reduce weeds and disease
by 50% to 80%.
The following grass cut heights are based an adequate
moisture conditions and normal thatch buildup in a
healthy lawn. Some locations and applications may
require slightly different cut heights. If in doubt,
consult your local lawn professional for assistance.
Grass Types
Best Cut Heights
Bermudagrass
Bluegrass
Buffalograss
Ryegrass
Tall Fescue
Zoysiagrass
1 - 2”
2 - 3”
11/2 -3”
2 - 3”
3 - 31/2
1 - 3”
”
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OPERATION INSTRUCTIONS
TO LIFT SEAT:
To lift the seat, move the control levers to the neutral
“OUT” position. Unhook the seat damper by rotating
the clip of the retaining pin off of the clevis end and
remove the retaining pin. Remove the clevisend of
the seat damper from the seat hold down bracket
and replace the pin and rotating pin clip to lock them
in place. Release the seat latch and rotate the
counterbalanced seat support frame upward and
forward.
To return the seat to the operating position, push the
counterbalance seat frame support rearward and down
until it rests firmly on the tractor frame. Reconnect the
seat damper by reversing the order of removal as stated
above.
SPRINGS:
Three seat springs are provided. The center spring may be
removed for a softer ride.
25
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OPERATION INSTRUCTIONS
TO FREE WHEEL MACHINE
(UNLOCK TRANSMISSION):
Always turn off engine before engaging or disengaging the hydro
release (free wheel) valves. Never attempt to move the valves with
the engine running.
The hydro release valves are located beneath the seat on the top of
the hydro pumps on each side of the machine. To unlock the
transmission, lift the seat (see Page 25), rotate the transmission
hex valve located on the top of each transmission approximately one
turn counter-clockwise.
To re-engage the transmission, rotate each transmission hex valve
clockwise to the end of its travel. Return the seat to the operating
position.
Note: Before pushing or towing the tractor, the transmission
must be unlocked and the parking brake released. The
tractor should never be pulled more than two miles per
hour or for any appreciable distance.
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CARE AND MAINTENANCE
CAUTION
Before performing any maintenance, turn off engine,
allow to cool & remove key.
Use extreme care when working on machinery.
Do not wear watch or jewelry. Do not wear loose fitting clothes,
and observe all common safety practices with tools.
MAINTENANCE SCHEDULE
•Check deck drive belt tension adjustment.......................................after 5 hours break-in
(adjust spring tension to 7 to7-1/2 inside to inside spring hook dimension.
Check belt tension periodically. Make adjustments as necessary)
•Check deck serpentine belt.............................................................after 20 hours break-in
(adjust bumper to approximately 1/2” thick)
•Check crankcase oil level.................................................................................before each use
•Clean grass from hydrostat fans..................................................................before each use
•Clean grass & debris from muffler & manifold area.................................before each use
•Check air intake screen......................................................................................after each use
•Clean grass under deck.....................................................................................after each use
•Check tire pressure...............................................................................................every 10 hours
•Inspect mower blades for sharpness................................................................every 10 hours
•Clean air filter element.........................................................................................every 25 hours
•Check hydrostatic transmission fluid..................................................................every 25 hours
•Grease all zerks.......................................................................................................every 50 hours
•Check drive and fan belt......................................................................................every 50 hours
•Replace air filter element..............................................................annually or every 100 hours
•Check spark plugs........................................................................annually or every 100 hours
•Change engine oil filter........................................................................................every 100 hours
•Change engine crankcase oil.........................................(5 hours break-in) every 100 hours
•Change hydrostat oil & oil filter................................(100 hours break-in) every 500 hours
27
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CARE AND MAINTENANCE
ENGINE:
For complete maintenance and operating information of the
engine, please refer to the maintenance instructions furnished
by the engine manufacturer and included in your Zero Turn
Radius mower information packet.
Note: Air intake screen must be kept clean. If plugged, engine
may be seriously damaged by overheating.
BATTERY:
Battery contains sulfuric acid electrolyte which is
poisonous and corrosive.
CAUTION
•This is a maintenance-free battery and the fluid level
cannot be checked.
OFF SEASON BATTERY STORAGE:
DO NOT remove battery from mower.
Clean top of battery and terminals with baking soda and water.
Identify each cable so they can be reconnected to the correct
terminal.
Disconnect cables from terminals. ALWAYS disconnect ground
cable first and reconnect last.
Charge battery.
TIRES:
Correct tire pressure is essential for efficient operation of the
mower. Check tire pressure periodically. Inflate tires to the
pressure listed below.
Front tires
Rear tires
-
-
16-20 lbs.
8-14 lbs.
Lug nuts or lug bolts should be checked regularly for tightness.
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CARE AND MAINTENANCE
CAUTION
Stop engine and remove ignition key for safety.
Wear heavy, thick gloves when holding onto
cutter blade, avoid the sharp edge of the blade.
MOWER BLADES:
Check sharpness of mower blades after every 10 hours of
operation. To sharpen blades, proceed as follows.
1.
Remove bolt and flat washer mounting blade on shaft.
Remove blade.
2.
3.
Blades should be discarded when worn excessively.
Sharpen blade with a hand file, electric grinder or blade
sharpener. Wear gloves and eye protection when
sharpening. Grind blade at original 25 degree bevel.
4.
5.
Check balance of blade by positioning the blade on a
nail or blade balance pedestal. Grind the blade on the
end that is heavier until both sides balance.
Install blade, flat washer & bolt. Make sure to tighten
bolt to 60 ft. lbs.
DANGEROUS!
DO NOT USE
BLADE IN THIS
CONDITION!
New Blade
When notch starts,
discard blade
BELTS:
Check belts every 50 hours. Replace any belts found to be in poor
condition.
29
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CARE AND MAINTENANCE
LUBRICATION:
1.
2.
3.
Engine: Follow engine manufacturer’s recommendation.
Deck spindles: Lubricate with 3 “shots” only, every 100 hours.
Mower chassis: Lubricate with 3 “shots” only, every 50 hours (see
zerk locations below).
30
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CARE AND MAINTENANCE
CHECKING & REPLENISHING OIL IN HYDROSTATIC
TRANSMISSION:
Dirt or water in oil can ruin the
hydrostatic transmissions.
Check the oil level in hydrostatic transmission oil
reservoir after every 25 hours of usage. Clean the
oil reservoir cap and the area around it prior to
removal. Check the oil level. Oil should be
approximately 1-3/8” below top of oil tank. Replenish
as needed with SAE 20W-50 motor oil. DO NOT
OVERFILL. When checking the oil level, be very
careful to keep the reservoir clean.
Change the oil in the reservoir and hydrostat
transmission oil filter after the first 100 hours of use.
Then every 500 hours after that. Remove the filter
and be sure all oil has drained from the reservoir.
Replace with new filter and SAE 20W-50 motor oil.
Please dispose of used oil at proper collection centers -
protect your environment
31
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CARE AND MAINTENANCE
PARKING BRAKE ADJUSTMENT
1.
2.
Loosen the locking screw on the top
knob of the brake engaging handle.
Rotate it clockwise to increase and
counter-clockwise to decrease brake
holding power. As the brake holding
power is increased, the force required
on the handle to engage the brake
increases.
3.
4.
Set the brake for the holding power
required for the intended use and the
desired force required to activate it.
Retighten the knob locking screw.
32
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CARE AND MAINTENANCE
HEADLIGHT ADJUSTMENT
1.
2.
Loosen the 1/2” retaining nut underneath the
headlight and slide the headlight forward out of
the fuel tank.
Loosen the 1/2” nut on the “U” shaped holding
bracket and swivel the headlight vertically to
adjust the height of the beam. Tighten the
bracket nut.
3.
4.
Replace headlight in fuel tank.
Swivel the headlight horizontally to illuminate
the desired area and tighten the headlight
retaining nut.
33
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CARE AND MAINTENANCE
HYDROSTATIC PUMPS:
Before each use, check to be sure that the cooling fins of
the hydrostatic pumps are clean. Excessive accumulation
of oil, dirt, or trash may cause the pumps to overheat.
NEVER WASH ACROSS TOP OF RESERVOIR WITH
WATER OR STEAM. Fill reservoir as required per the
maintenance schedule listed in this book.
HYDROSTAT DRIVE BELT
REPLACEMENT PROCEDURE:
To remove hydrostat pump drive belt:
(The hydrostat pump drive is equipped with a spring
loaded belt take-up).
1.
2.
Raise seat. (See instructions on Page 25).
Remove hold down bolts from belt cover. Remove
belt cover.
3.
Rotate the spring loaded take-up idler towards the
left hand hydro pump to provide belt slack for
removal.
4.
Remove belt.
To install hydrostat pump drive belt:
1.
Rotate the spring loaded take-up idler towards the left
hand hydro pump.
2.
3.
4.
Install belt per diagram.
Re-attach belt cover.
Return the seat to the operating position.
34
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CARE AND MAINTENANCE
STEERING CONTROL ADJUSTMENTS:
To adjust neutral:
1.
2.
Lift seat (see instructions on Page 25).
Block up the unit so that the drive wheels are off
the ground.
3.
4.
5.
6.
Loosen ball joint jam nuts on control rod.
Note: The front jam nuts are left hand threads.
With steering control arms in the “out” neutral
position, start the engine and run at fast idle.
Adjust the neutral position by turning the control
rod until the wheels do not rotate.
Re-tighten the jam nuts on the control rod and
check to see that the drive wheels are not turning.
Repeat steps 3-6 for the other side.
7.
8.
9.
Shut off engine before removing the blocks.
Return the seat to the operating position.
To adjust neutral springs:
1.
Loosen set screws of front and rear spring stop
collars located on the control rods. (Requires a
1/8” Allen wrench).
2.
3.
Move control handle full forward.
Move front spring stop collar rearward until it
compresses spring approximately 1/16” and
tighten collar set screw.
4.
5.
Move control handle full rearward.
Move rear spring stop collar forward until it
compresses spring approximately 1/16” and
tighten collar set screw.
6.
Repeat steps 1-5 for opposite side.
35
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CARE AND MAINTENANCE
STEERING CONTROL ADJUSTMENTS (continued):
To adjust steering control levers:
1.
Loosen the front and rear bolts retaining the
bellows hold down plate and slide the bellows
and plate up the steering lever to expose the
steering control mechanism.
2.
3.
4.
Move the levers inboard to the operating
position.
Loosen the set screw of the clamp collars which
lock the upper arms to the lower arms.
Raise or lower the arms for desired height. There
is approximately 3” of height adjustment available.
Upper shaft should have a minimum of 1-1/2”
engagement in lower shaft.
5.
6.
Rotate arms until they have the desired
orientation front to back.
Tighten the clamp collar set screws.
36
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CARE AND MAINTENANCE
STEERING CONTROL ADJUSTMENTS (continued):
To adjust “In” position of the steering controls
1.
2.
Move the levers inboard to the operating position.
Adjust the steering lever stops until the steering
levers have the desired clearance.
To adjust for straight forward tracking.
1.
Drive tractor with both control levers in the full
forward position.
2.
3.
Stop the machine and shut off the engine.
Adjust the forward stop of the control levers on
the side which appears to be faster to limit the
forward travel of the control levers until the
mower tracks in a straight line.
Note: Variations in the turf and tire pressure can
cause variations in speed and tracking.
When all alignment adjustments are satisfactory, slide
the hold down plate and bellows down the control levers
and secure with screws.
37
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CARE AND MAINTENANCE
LEVELING THE DECK:
1.
2.
Set the tire pressure on all four tires.
Front casters must be rotated in the direction of
forward travel.
3.
4.
Move the tractor to a hard level surface.
Put the mower deck in the number 3 deck height
position.
5.
6.
Loosen the jam nuts on the front and rear deck
hangers.
Rotate the 2 outer spindles so the blades point
outboard.
7.
8.
Adjust front hangers to level deck side to side.
Rotate all 3 spindles until the blades are fore
and aft.
9.
Adjust rear hangers until deck is level to 1/8
higher in the rear.
10.
Retighten the jam nuts on the front and rear
deck hangers.
38
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STANDARD SERVICE PARTS LIST
MODEL ZTR 8025:
Blades (60”) standard:
P/N 12421
P/N 12451
P/N 12508
P/N 12339
P/N 12452
P/N 12509
low lift:
Gator:
Blades (72”) standard:
low lift:
Gator:
Engine to Mower Deck Belt:
Serpentine Belt (60”):
Serpentine Belt (72”):
Engine to Hydro Belt:
P/N 12172
P/N 9758
P/N 12033
P/N 12012
Hydrostatic Transmission Filter:
P/N 7252
KOHLER AIR AND OIL FILTER PART NUMBERS:
Refer to engine manufacturer’s manual for recommen-
dations regarding frequency of service required for
engine oil changes and air filter maintenance.
Protect your engine investment, use only original
equipment filters.
MODEL ZTR 8025 (25 HP):
Air Filter & Pre-Cleaner Kit
Engine Oil Filter
78003
78006
IMPORTANT:
Some applications, extreme dirt conditions, or the use of
a grass catcher may require that the engine used on the
Model ZTR 8025 be fitted with an optional Kohler fresh
air filter system. Check with your engine service center
for availability.
39
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TROUBLESHOOTING
1.
ENGINE WON’T TURN OVER
Mower blades engaged- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -disengage blades
Drive not in neutral - - - - - - - - - - - - - - - - - - - - - - -move control levers to neutral “OUT”
Circuit breaker trips- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - reset breaker
Dead battery- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - charge or replace
Solenoid- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Ignition switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Starter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
Parking brake not on- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -engage parking brake
2.
3.
ENGINE WILL TURN OVER BUT WON’T START
No fuel - - - - - - - - - - - - - - refuel and/or clean or replace fuel filters/open fuel valve
Over or under choked- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -adjust choke
Spark plug not firing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - check spark plug
Carburetor maladjusted- - - - - - - - - - - - - - contition or reset gap*/consult dealer
Ignition Switch- - - - - - - - - - - - - - - - - - - - - - - - - - -readjust carburetor*/consult dealer
HARD TO START ENGINE
Fuel line clogged- - - - - - - - - - - - - - - - clean fuel line/check fuel filter/open fuel valve
Faulty fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Spark plug wire loose or grounded- - - - - - - - - - - - - - - - - - - - -check spark plug wires
Spark plugs faulty or improperly gapped- - - - - - - - - - - - - - - - - - - - - check spark plug
Electronic ignition defective- - - - - - - - - - - condition or reset gap*/consult dealer
Dirty or maladjusted carburetor- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
4.
5.
ENGINE STARTS BUT CUTS OUT
Water in fuel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - drain old fuel-replace with new fuel
Clogged fuel line- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - check fuel filter/clean fuel line
Fuel tank vent plugged- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - check vent
Faulty fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Maladjusted carburetor- - - - - - - - - - - - - - condition or reset gap*/consutl dealer
Engine dies when control levers moved “IN”- - - - - - - - - - - - -release parking brake
ENGINE KNOCKS
Low oil level- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -check and add oil
Ignition timing off- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Fuel octane too low- - - - - - drain & replace with higher octane fuel
Over heated engine- - - - - - - - - - - - - - - - -shut off engine/allow to cool
*See engine manual for engine adjustments
40
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TROUBLESHOOTING
6.
ENGINE OVERHEATED
Air intake screen or fins clogged- - - - - - - - - - - - - - - - - clean intake screen and fins
Fuel mixture too lean- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - readjust carburetor*
Improper ignition timing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Oil level too low or too high- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - adjust oil levell
Running engine too slow- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -run engine faster
(NOTE: Always mow at full throttle setting)
7.
8.
ENGINE SOMETIMES SKIPS AT HIGHER SPEEDS
Incorrect ignition timing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
Carburetor maladjusted- - - - - - - - - - - - - - - - - - - - - - -- - - - - - - -readjust carburetor*
Faulty spark plug- - - - - - - - - - - - - - - check spark plug or condition and reset gap*
ENGINE RUNS BUT MOWER WON’T MOVE FORWARD
Drive belt broken or slipping- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -replace drive belt
Pump arm loose or disconnected- - - - - - - - - - - - - - - - - - - - - - - -tighten or reconnect
Hydraulic oil system low- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - add oil
By-pass valves in free wheel position- - - - - - - - - - - - - - - - - - - - tighten by-pass valves
Hydrostat oil filter plugged- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - replace filter
Bad pump or wheel motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
9.
ENGINE STALLS WHEN BLADES ARE ENGAGED
Operator not on seat- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -sit on seat
Faulty interlock system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Bad Blade spindle bearing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
Deck drive belt not properly routed- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - reroute
Blades blocked by foreign material- - - - - - - - - - - - - - - - - - - - - - - - - -clean under deck
10.
11.
ENGINE BACKFIRES
Carburetor maladjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -readjust carburetor
ENGINE IDLES POORLY
Carburetor maladjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -readjust carburetor
Improper spark plug gap- - - - - - - - - - - - - - - - - - - - - - - - - - - - - check and re-gap plug*
*See engine manual for engine adjustment
41
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NOTES
42
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OWNER
INFORMATION
DIXON INDUSTRIES, INC.
a BLOUNT International Inc. Co.
P.O. Box 1569
Coffeyville, Ks 67337-0945
620-251-2000
FAX 620-251-4117
Date Purchased _________________________________
Mower Model Number ____________________________
Mower Serial Number ____________________________
Purchased From ________________________________
Name
________________________________
Address
________________________________
DATE OIL CHANGED:
DATE ENGINE TUNED:
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
43
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ZTR®Mowers
The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects or other
reproductive harm.
WARNING:
Dixon® and ZTR® are registered trademarks of Dixon Industries, Inc.
DIXON INDUSTRIES, INC.
a BLOUNT International Inc. Co.
P.O. Box 1569
Coffeyville, Ks 67337-0945
620-251-2000
8000 Series(Gas)
Model 8025
Part No. 13637-xxxx
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