Dixon Lawn Mower ZTR 8025 User Manual

Operator's Manual  
8000 SERIES  
ZTR® MOWERS  
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INDEX  
SAFETY ............................................Pages  
WARRANTY POLICY..........................Page  
SPECIFICATIONS .............................Page  
4-9  
10  
11  
SEAT ADJUSTMENT...........................Page  
CONTROLS .......................................Pages  
OPERATION INSTRUCTIONS ............Pages  
CARE AND MAINTENANCE ................Pages  
STANDARD SERVICE PARTS LIST .....Page  
TROUBLESHOOTING.........................Pages  
12  
13-16  
17-22  
23-33  
34  
35-36  
8000 Series  
Part No. 13092-0700  
3
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SAFETY  
RIDING LAWNMOWERS, IF IMPROPERLY OPER-  
ATED, CAN CAUSE SERIOUS INJURY OR DEATH  
The most common causes of injury to the operator or bystander...  
BLADE CONTACT  
TIP-OVER  
BACK-OVER  
RUN-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  
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.  
5
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SAFETY  
Thiscuttingmower iscapableofamputatinghands&feet,  
andthrowingobjects.  
Failuretoobservethefollowingsafetyinstructionscouldresultin  
seriousinjuryor 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.  
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.  
Maintain or replace safety and instruction labels, as necessary.  
6
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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.  
Useextracarewith grasscatchersor other attachments. Thesecan changethestabilityofthemower.  
Keepallmovement ontheslopesslowandgradual. Donot makesuddenchangesinspeedordirection.  
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.  
Donot mowneardrop-offs,ditches,orembankments. Themowercouldsuddenlyturn overifawheel  
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.  
7
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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 watch-  
ful 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.  
8
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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,  
If fuel is spilled on clothing, change clothing immediatley.  
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 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 equip-  
ment parts, when necessary.  
9
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DIXON INDUSTRIES, INC.  
a BLOUNT company  
AIRPORT INDUSTRIAL PARK  
PO BOX 1569  
COFFEYVILLE KS 67337 0945  
316 251 2000  
FAX 316 251 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.  
2.  
Warranty applies only to original retail purchaser of new and unused mowers and accessories.  
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.  
4.  
5
Battery warranty: Limited to 90 days from date of purchase.  
Accessories Warranty (Grass Catchers, Snow Blades, Covers, etc.): Limited to 90 days from date of purchase.  
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/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.  
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  
Address  
Dealership  
Address  
Owner's Signature  
Dealer's Signature  
10  
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SPECIFICATIONS  
Specifications go here  
8000 Series  
CHASSIS:  
BODY:  
SEAT:  
11 GA - rectangular tube  
Folded sheet metal.  
Designedfor operator comfort withpaddedbackandarmrests. Seat isadjustable  
fore and aft.  
MOWER DECK:  
2 Decks are available. Both decks are made of 10 GA fabricated welded  
construction with 7 -" GA reinforcement plate. 3 blades combine for either a 60"  
or 72" cut width. Cut height approximately1.5" to6" via 11position lift handle.  
BLADE DRIVE:  
DRIVE SYSTEM:  
Electric clutch  
Each rear wheel is independently driven by a HydroGear BDA pump and White  
CE wheel motor.  
ENGINE:  
25HP Kohler Command, 4-Cycle, V-Configuration, Overhead Valve, Air-  
Cooled,Gasoline,VerticalShaft,AluminumHead,andCrankcasewithCastIron  
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: Electricbykeyswitchoperation withsafetyinterlockson parkingbrakeandblade  
drive clutch.  
TIRES:  
Front  
Rear  
13-6.5x6  
23-10.5x12  
RECOMMENDED  
TIRE PRESSURE:  
Front  
Rear  
12 lbs.  
12 lbs.  
CAPACITIES:  
DIMENSIONS:  
NOTE:  
Fuel - 11.5 gallons (approx)  
Hydrostat oil tank - 4 quart with in-line 40 micron filter  
Hydrostat oil recommendation, refer to page 36  
Engine - 2 qts. SAE 10W30 (with filter)  
Width  
Height  
Length  
Weight  
73.5"(60" Deck), 85.5"(72" Deck)  
54"  
87"  
1020 lbs.(60" Deck), 1054 lbs.(72" Deck)  
Additional information provided in service instructions under the individual  
component.  
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE  
11  
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SEAT ADJUSTMENT INSTRUCTIONS  
8000 Series Models  
FORE & AFT ADJUSTMENT  
1.  
2.  
3.  
Grasp seat slide adjuster and move it into adjustment position.  
Slide seat forward or backward.  
Release seat slide adjuster.  
SEAT BACK ADJUSTMENT  
Rotate knob clockwise to recline.  
1.  
2.  
Rotate knob counter-clockwise to raise.  
12  
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CONTROLS  
SHOW HOW TO REMOVE BOOT & RAISE  
AND LOWER & ROTATE CONTROL  
HANDLES  
ADD INFO ON HEADLIGHT POSITION ON  
START SWITCH  
13  
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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.  
.
Engage parking brake before starting engine  
CAUTION  
TO SET PARKING BRAKE:  
The hand operated parking brake is located at left hand side  
of mower.  
To engage brake, pull upward.  
To release brake, move lever downward.  
NOTE:  
Always set parking brake before dismounting.  
Release parking brake before moving mower.  
HYDRO-GEAR DRIVE SYSTEM:  
Allows the mower to turn on its own axis (zero turning radius).  
Each lever controls one side of the mower.  
NOTE: The pressure required to operate the mower is very light.  
14  
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CONTROLS  
SHOW HOW TO REMOVE BOOT & RAISE  
AND LOWER AND ROTTTE CONTROL  
HANDLES.  
ADD  
15  
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CONTROLS  
BLADE DRIVE:  
Located on control panel, on operator's right.  
To engage blades: Pull up on the switch.  
To disengage blades: Push down.  
MOWER DECK CUT HEIGHT LIFT LEVER:  
Located to the right and front of operator.  
Controls the cutting height.  
Eleven positions of adjustment.  
NOTE: Always use high position for transport.  
16  
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OPERATION INSTRUCTIONS  
ThesafeandsuccessfuloperationoftheModelZTR8000Serieswilldependupontheoperator  
having the correct knowledge of all controls used on the mower and making good judgements  
about the terrain to be mowed.  
NEVER allowanyonetooperatethemowerwithoutcompleteknowledgeofallcontrolsandtheir  
functions.  
During initial operation, "learning to drive", set throttle at slow speed.  
Sound judgement by the owner will prevent accidents.  
BEFORE OPERATING MOWER:  
1. Read engine manufacturer's operating and maintenance instructions.  
2. Discuss proper maintenance with your dealer.  
3. Read and observe all safety instructions on your mower and in the  
manual.  
4. Check engine oil.  
5. Check gas cap to be sure it is in place.  
6. Be sure parking brake is on.  
7. Mower blade drive is off.  
8. Know how to stop engine. (Turn key to off position)  
17  
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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 switches interlocked for your safety.  
1.  
2.  
The mower blades must be disengaged before the engine will start.  
The steering control levers must be in neutral "OUT" position before the  
engine will start.  
3.  
The engine will stop if the mower blade clutch is engaged when the  
operator leaves the driver's seat.  
4.  
The engine will stop if the brake is "SET" and the steering control levers  
are moved to the "IN" position.  
BLADE DRIVE SWITCH TEST: (Electric Clutch)  
a. With the electric blade drive switch turned on and  
the parking brake in "ON" position, engine should  
not turn over or attempt to start when key switch is  
moved to the start position.  
b. 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 weight slightly off of seat. Engine  
should stop.  
c. If any Safety Check fails, do not operate the mower  
until the system has been checked and repaired by  
anAuthorized Dixon ZTR Dealer.  
18  
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OPERATION INSTRUCTIONS  
STARTINGINSTRUCTIONS:  
Cold Engine  
1. Push throttle control lever to 1/2 setting.  
2. Push choke control lever forward.  
3. Insert ignition key and turn to "Start" position. When engine starts, release ignition  
key. Key will return to "Run" position.  
4. Once engine starts to warm up, slowly push choke control lever back to the fully  
open position.  
5. Move throttle control lever to the wide open or maximum setting for actual opera-  
tion of the mower deck.  
6. Engine must be operated at wide open or maximum setting to insure adequate  
lubrication, cooling and cut quality of the mower deck.  
NOTE: Model ZTR 8025 will  
require a slightly longer  
warm up period using  
partial choke settings.  
19  
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OPERATION INSTRUCTIONS  
STARTING INSTRUCTIONS:  
Engine has been operated.  
1. Move throttle control lever to 1/4 to 1/2 setting.  
2. Insert ignition key and turn to "Start" position. When engine  
starts, release ignition key. Key will return to "Run" position.  
3. Move throttle control lever to wide open or maximum setting for  
actual operation of the mower deck.  
NOTE: Model ZTR 8000 Series may require partial choke setting  
to start  
even if the engine has been operated for a  
period of time.  
4. Engine must be operated at wide open or maximum setting to  
insure adequate lubrication, cooling and cut quality of the  
mower deck.  
CAUTION  
DO NOT operate the engine in an enclosed area  
due to the harmful exhaust gas produced.  
NOTE:  
On initial operation, set throttle at slow speed.  
Engine cannot be restarted when blade is engaged.  
Safety switches stop engine when operator leaves seat  
while  
mower  
blade is engaged.  
Always turn engine off when leaving mower.  
20  
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OPERATION INSTRUCTIONS  
In order to achieve optimum cutting performance, please read and follow the  
tips listed below.  
Additional information can be found in the troubleshooting guide beginning on  
page 35.  
CAUTION  
Be sure that deflector is properly installed on  
the  
discharge chute.  
1. Set engine speed control to the wide open or full setting.  
2. Do Not Attempt To Cut Grass When It Is Wet. Wet grass will clog the under-  
side of the deck and discharge area.  
3. If the grass is tall, place the mower deck cut height lever in the top or sec-  
ond notch. "Initially" overlap cutting swaths instead of a full swath with  
each pass. Some applications may require a second cutting.  
4. Keep The Underside Of The Mower Deck Clean. Frequent removal of dried  
grass and dirt will allow the clippings to discharge correctly.  
5. Maintain Sharp Blade(s) Throughout The Cutting Season.  
GRASS HEIGHT SUGGESTIONS:  
Correct mowing height can reduce weeds and disease by 50% to 80%  
The following grass cut heights are based on adequate moisture conditions and  
normal thatch buildup in a healthy lawn. Some locations and applications may  
require slightly different cut heights. If in doubt, consult your local lawn pro-  
fessional for assistance.  
Grass Types:  
Best Cut Heights:  
Zoysia  
2" - 2 1/2"  
1 1/2" - 3"  
1 1/2" - 3"  
1 1/2" - 2"  
Blue Grass  
Fescue Blends  
St. Augustine (Mid South)  
St. Augustine (Deep South)  
Tifton Bermuda  
3" - 4"  
1 1/2"  
Centipede  
1 1/2" - 2"  
1 1/2" - 2"  
2"  
Common Bermuda  
Bahia/Argentina/Pensacola  
21  
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CARE AND MAINTENANCE  
CAUTION  
Before performing any maintenance, turn off engine, allow to cool, remove key  
and disconnect spark plugs. 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 drive belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
every 50 hours  
(20 hours break-in)  
Check crankcase oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
before each use  
Clean grass from Hydrostat fans and cooling fans . . . . . . . . . . . . . . . before  
each use  
Check air intake screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
after each use  
Clean grass under deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
after each use  
Check tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
every 10 hours  
Check battery fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
every 10 hours  
Sharpen mower blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
every 10 hours  
Clean air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
every 25 hours  
Check hydrostatic transmission fluid . . . . . . . . . . . . . . . . . . . . . . .  
every 25 hours  
Service air filter element. . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
every 100 hours  
Change engine crankcase oil . . . . . . . . . . . . . . . . . . . . . . . . . . every  
100 hours  
(5 hours break-in)  
Change engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
every 200 hours  
Change hydrostat oil & oil filter . . . . . . . . . . . . . . . . . . . . . . . . .  
every 500 hours  
(100 hours break-in)  
Replace air filter element . . . . . . . . . . . . . . . . . . . . . . annually or  
every 500 hours  
22  
Check spark plugs . . . . . . . . . . . . . . . . . . . . . . . . annually or every  
500 hours  
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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 manufaturer  
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 over heating.  
CAUTION  
Battery electrolyte is a poisonous and corrosive  
acid solution. Avoid spilling on skin,  
sulfuric  
BATTERY:  
eyes and clothing.  
Check the fluid in the battery at frequent intervals.  
Keep fluid level above the plates in each cell, using distilled water.  
OFF SEASON BATTERY STORAGE:  
Identify each cable so cables can be reconnected to correct terminals.  
Disconnect cables from terminals.  
ALWAYS disconnect ground cable first and reconnect last.  
Charge battery.  
DO NOT remove battery from mower.  
Clean top of battery and terminals with baking soda and water.  
TIRES:  
Correct tire pressure is essential for efficient operation of the mower. Check  
pressure periodically. Inflate tires to the pressure listed below.  
tire  
Front tires -12 lbs.  
Rear tires -  
12 lbs.  
Lug nuts or lug bolts should be checked regularly for tightness.  
23  
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CARE AND MAINTENANCE  
Stop engine, remove ignition key and spark plugs for  
safety. Wear heavy, thick gloves when holding onto  
cutter blade, avoid the sharp edge of the blade.  
CAUTION  
MOWER BLADES:  
Check sharpness of mower blades after every 10 hours of operation.  
blades, proceed as follows.  
To sharpen  
??  
A.  
Remove bolt, lock washer, and cup washer mounting blade on  
Remove blade.  
shaft.  
B.  
C.  
Blades should be discarded when worn excessively.  
Sharpen blade with a hand file, electric grinder or blade sharp-  
ener. Wear  
gloves  
and eye protection when sharpening.  
Grind blade at original 25  
degree bevel.  
D.  
Check balance of blade by positioning the blade on a nail or  
pedestal. Grind the blade on the end that is  
blade balance  
heavier until both sides bala
DANGER-  
OUS!  
DO NOT USE  
E.  
Install blaoBltL.ADEMINake sure to  
THIS  
CONDITION!  
tighten bolt to 60  
New  
Blade  
25  
When notch starts,  
degrees  
discard blade  
BELTS:  
Check belts every 50 hours. Replace any belts found to be in poor  
condition.  
All belts are equipped with spring loaded belt tighteners and do not  
require tightening  
adjustments.  
24  
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CARE AND MAINTENANCE  
LUBRICATION:  
A.  
B.  
C.  
Engine: Follow engine manufacturer's recommendation.  
Deck spindles: Lubricate with 3 "shots" only, every 100 hours.  
Hydrostatic transmission and filter (follow instructions listed below).  
Dirt or water in oil can ruin the hydrostatic transmissions.  
CHECKING & REPLENISHING OIL IN HYDRO-  
STATIC TRANSMISSION  
Check the oil level in hydrostatic transmission oil reservoir after every 25  
hours of usage. Clean  
removal. Check the oil level on the dipstick.  
the oil reservoir cap and the area around it prior to  
The proper oil level  
should register between the marked hole on the dipstick and the end of the  
dipstick. Replenish as needed with 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  
filter and 20W-50 Mobil Super II.  
reservoir. Replace with new  
Oil Reservoir Cap  
Dipstick  
new instructions & graph-  
ics. no dipstick  
Fuel  
Cap  
Please dispose of used oil at proper collection centers - protect your environment  
25  
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CARE AND MAINTENANCE  
PARKING BRAKE ADJUSTMENT  
With the brake handle in the release position, remove the cotter pin from the castle nut. Insert  
a 0.010 feeler gauge between the brake disc and the brake puck.  
Tighten the castle nut with  
the feeler gauge inserted until the gauge fits snugly between the disc and puck. The gap  
should not be so tight that the feeler gauge cannot be reinserted after removal. Back the  
nut to the closest pin hole and reinsert the cotter pin. Repeat for other side. See  
castle  
picture  
below.  
Castle  
Nut  
.010 between Brake Disk and Brake Puck  
Brake Linkage Spring  
Stop  
Actuating  
Lever  
26  
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CARE AND MAINTENANCE  
HYDROSTATIC TRANSMISSIONS:  
Before each use, check to be sure that the cooling fins of the hydrostatic  
transmissions  
may cause the transmissions to  
OF RESERVOIR WITH WATER OR STEAM.  
maintenance schedule listed in this book.  
are clean. Excessive accumulation of oil, dirt, or trash  
overheat. NEVER WASH ACROSS TOP  
Fill reservoir as required per the  
HYDROSTAT DRIVE BELT REPLACEMENT PRO-  
CEDURE:  
(The hydrostatic drive is equipped with a manual belt take-up).  
A.  
of the  
B.  
Remove the 3/8" locknut, washers, and rubber spacer from the rear  
assembly.  
Allow the idler arm/pulley to swing forward towards the fornt of the  
mower. Remove old  
C. With the belt in place on all pulleys, reinsert the rubber spacer, wash-  
ers, and 3/8" locknut. Tighten 3/8" locknut until rubber spacer is  
deflected approximately 1/8" to 3/16". Make sure belt is not too tight.  
Belt deflection or movement should be approximately  
1/4" to 1/2" when measured at mid-point between hydro and idler pul-  
belt if required. Replace with new belt.  
ley.  
Hydrostat Drive  
Pulley  
Hydrostat Drive  
Belt  
Motor Pulley  
Idler  
Pulley  
3/8" Pin and Rue-Ring  
3/8" bolt, lockwasher & heavy  
new instructions & graphics.  
washer  
27  
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CARE AND MAINTENANCE  
STEERING CONTROL ADJUSTMENTS  
new instructions & graphics.  
A.  
To Adjust Neutral:  
1.  
2.  
3.  
Remove the fender skirts from each side of the machine.  
Block up the unit so that the Drive Wheels are off the ground.  
Start the engine and run at a fast idle with the Steering control levers  
position.  
in the "out"  
4.  
Loosen the locknuts tightened against the rod end ball joints in the  
Upper Linkage  
Assembly.  
NOTE: One of these is a left hand nut and will have to be turned  
backwards.  
5.  
Adjust the Neutral Position by turning the rod in the upper linkage  
until the wheel stops  
6. Retighten the nuts on the Upper Linkage Assembly and check to see  
that the drive  
turning.  
wheel is still not turning.  
Repeat steps 1-6 for the other side.  
Shut off engine before removing the blocks.  
7.  
8.  
B.  
To Adjust "IN" Position of the Steering Controls:  
1.  
Remove the two front bolts, lockwashers, and washers which hold the  
Pull the boot from the hole in the fender cap, exposing the cast iron  
fender cap.  
2.  
lever.  
3.  
Using a 5/32" Allen wrench, turn the setscrew to adjust the stop.  
Replace the boot into the hole in the fender cap.  
4.  
5.  
Replace the two front bolts, lockwashers and washers.  
C.  
To Align Handles:  
Sit on the seat and push the control levers full forward and full backward. If  
the ends do not  
match, the handles may be adjusted as follows:  
1.  
Locate setscrew stops in the steering control lever base which stop the  
lever in each  
direction.  
28  
NOTE: The one at the rear is the stop for FWD and the one in the  
REV.  
front is the stop for  
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CARE AND MAINTENANCE  
STEERING CONTROL ADJUSTMENTS (continued):  
D.  
Adjusting for Straight Forward Tracking:  
In large open area, actuate the control handles into the full forward position. If  
the mower veers in either direction (left or right) some adjustment is necessary.  
1.  
If the mower veers to the right, then the right hydrostat needs to be  
sped up. If the  
mower veers to the left, then the left hydrostat  
needs to be sped up.  
2.  
3.  
Stop the machine and shut off the engine.  
Slightly loosen the bolt at the lower end of the upper linkage assembly  
on the side that  
is slower. Using a 1/8" Allen wrench turn the  
setscrew 1/4 turn in. It may take several  
mower to track straight forward.  
test drives to get the  
4.  
Once the tracking is to the operator's liking, completely tighten the  
bolt on the control  
earlier.  
linkage assembly that was loosened  
5.  
Recheck to make sure neutral adjust has not been effected, see  
Inward Stop  
Steering Control  
Lever  
procedure A.  
Setscrew  
new in-  
structions &  
Reverse Stop  
Setscrew  
Forward  
Stop  
Setscrew  
graphics.  
Access  
Rod End Ball  
Hole  
LH Locknut  
Joint  
Turn this  
rod to  
Adjust  
Upper linkage As-  
Neutral  
sembly  
Setscrew used to  
adjust Forward Tracking  
RH Locknut  
Loosen Bolt on Linkage  
29  
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CARE AND MAINTENANCE  
LEVELING THE DECK  
A.  
B.  
Set the tire pressure on all four tires.  
Move the tractor to a hard, level surface (i.e. concrete or blacktop).  
board under all four corners of the deck shell, just inside  
Place a 2x4  
of the anti-scalping  
The deck must rest on the  
wheels. Lower the deck down onto the boards.  
boards, not the anti-scalping sheels.  
Adjust the deck hangers longer or shorter  
comes off of the boards. Remove the boards and verify that  
until the deck "just"  
the  
deck is hanging on all four deck hangers, re-adjust if necessary. Lock the  
jam nuts on the deck hangers. (Note: the two rear deck hangers will be  
easier to  
adjust in the  
fender skirts are removed).  
new instructions & graphics.  
Rear Deck Hanger  
(one each side)  
Front Deck  
Hanger  
(one each  
side)  
2 x 4 board, one each corner, just  
inside of anti-scalping wheel  
30  
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CARE AND MAINTENANCE  
PROCEDURE FOR RAISING AND LOWERING THE  
DECK  
FOR SERVICING  
new instructions & graphics.  
RAISING THE DECK:  
A.  
Remove cut height adjustment pin and completely lower the cut height  
lever. Re-insert the cut height adjustment pin into the 3-1/2"  
adjustment  
cut height position (this  
the lowest position.  
will lock the cut height adjustment lever into  
B.  
Flip up the foot deck to allow access to the engine to deck drive blet.  
deck drive belt off the center spindle. Hook the  
Roll the engine to  
engine to deck drive belt onto the bolt  
foot deck support angle.  
protruding out of the top of the  
C.  
latch. Repeat for  
D. Position the front caster sheels so they are away from the deck (such  
as the tractor would bve traveling in reverse).  
E. Attached a hoist to the deck lift bolt. lift the nose of the deck until the  
deck is standing vertical and the deck latch engages.  
Lift the rear corner of the deck and disconnect the rear deck mounting  
the other side.  
IMPORTANT NOTE: MAKE SURE THAT THE DECK IS LIFTED FAR  
ENOUGH FOR THE DECK LATCH TO FULLY ENGAGE THE LOCKING  
PIN (LOCATED ON THE LEFT SIDE OF THE DECK MOUNTING SUS-  
PENSION). THIS WILL PREVENT THE DECK FROM FALLING  
DOWN WHEN SERVICING THE UNDERSIDE OF THE MOWER  
DECK.  
LOWERING THE DECK:  
A.  
While lifting the nose of the deck disengage the deck latch from the  
the bottom of the deck towards the rear of the tractor  
locking pin. Push  
while holding the deck latch so  
deck until it rests on the ground.  
that it clears the locking pin. Lower the  
B.  
latch. Repeat for  
C. Roll the engine to deck drive belt back onto the center spindle. Insure  
Lift the rear corner of the deck and reconnect the rear deck mounting  
the otherside.  
that the engine  
to deck drive belt is installed onto all of the pulleys and  
idlers in the drive train.  
D.  
Lower the foot deck down into the operation position.  
31  
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CARE AND MAINTENANCE  
Cut Height Adjustment  
Pin  
Cut Height Adjustment  
Lever  
Locking  
Pin  
Deck  
Latch  
Foot  
Deck  
Center Deck Spindle  
Deck Lift  
Bolt  
new instructions & graphics.  
Rear Deck Mounting  
Front Caster Wheels positioned  
out of the way  
Latch  
Rear  
Corner  
MOWER SHOWN IN OPERATION POSITION  
Engine to Deck Drive Belt  
Deck Latch in locked  
position  
Hoist  
Foot Deck in up position  
MOWER SHOWN IN SERVICING POSITION  
32  
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STANDARD SERVICE PARTS LIST  
MODEL ZTR 8025:  
BLADES:  
60":  
72":  
P/N  
P/N  
BELTS:  
Engine To Mower Deck:P/N  
Serpentine Belt:  
Engine To Hydro:  
P/N  
P/N  
Hydrostatic Transmission Filter:  
P/N  
KOHLER AIR AND OIL FILTER PART NUMBERS:  
Refer to engine manufacturers manual for recommendations regarding fre-  
quency of service required for engine oil changes and air filter maintenance.  
Protect your engine investment, use only original equipment filters.  
Model ZTR 8025: 25HP  
Pre-Cleaner Foam Element  
Cartridge Air Cleaner  
Engine Oil Filter  
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.  
Listed below are the Kohler kit numbers required to adapt these  
components to the engine. Consult your dealer or a Kohler engine  
service center for additional information.  
Model ZTR 8025:  
availability  
25HP  
Check with xxxxxxx Dealer for  
33  
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TROUBLESHOOTING  
1. ENGINE WON'T TURN OVER  
------------------------------------------------------------------------------------------------  
Mower blades engaged  
--------disengage blades  
Drive not in neutral  
----------------------------------------------------------------move steering control levers  
Blown fuse  
Dead battery  
------------------------------------------------------------------------------------------------  
to neutral "OUT " position  
Solenoid  
Ignition switch  
------------------------------------------------------------------------------------------------  
-------------------------------replace fuse  
Starter  
---------------------charge or replace  
------------------------------------------------------------------------------------------------  
-------------------------------consult dealer  
2. ENGINE WILL TURN OVER BUT WON'T START  
------------------------------------------------------------------------------------------------  
No gas  
Over or under choked  
------------------------------------------------------------------------------------------------  
-------------------------consult dealer  
Spark plug not firing  
Carburetor maladjustment  
Ignition Switch  
----------------------------------consult dealer  
------------------------------------------------------------------------------------------------  
3. HARD TO START ENGINE  
-refuel and/or clean or replace fuel filters  
Fuel line clogged  
------------------------------------------------------------------------------------------------  
Faulty fuel pump  
Spark plug wire loose or grounded  
------------------------------------------------------------------------------------------------  
----------------adjust choke  
Spark plug(s) faulty or improperly gapped  
Electronic ignition defective  
-------------check spark plug  
--------------------------------------------------------------------------condition and reset  
Dirty or maladjusted carburetor  
gap*/consult dealer  
---------------------------------------------------------------readjust carburetor* or con-  
sult dealer for carburetor service  
4. ENGINE STARTS BUT CUTS OUT  
Water in gasoline  
Clogged fuel line  
Vent in fuel cap plugged  
--------------------------------------------------------------------------------------------  
Faulty fuel pump  
Maladjusted carburetor  
clean fuel line and check fuel filter  
------------------------------------------------------------------------------------------------  
Engine dies when control levers are moved "IN"  
---------------------consult dealer  
-----------------------------------------------------------------------------------check spark  
plug wires  
5. ENGINE KNOCKS  
----------------------------------------------------------------------------------check spark  
Low oil level  
Ignition timing off  
-------------------------------------------------------------------------------------------  
plug  
Fuel octane too low  
Over heated engine  
condition and reset gap*  
consult dealer  
readjust carburetor* or consult dealer for carburetor service  
-----------------------------------------drain old gasoline-replace with new gasoline and /  
or clean carburetor bowl  
-------------------------------------------------------------------------------clean carbure-  
tor bowl and or check fuel filter  
------------------------------------------------------------------------------------------------  
------------clean fuel line  
------------------------------------------------------------------------------------------------  
-------------------------check vent  
------------------------------------------------------------------------------------------------  
-------------consult dealer  
34  
---------D--o-w-n-lo-a-d-f-ro-m--W-w-w--.S-o-m-a-n-u-a-ls-.-co-m--. -A-ll-M-a-n-u-a-ls-S-e-a-r-c-h-A-n-dpDaorwknlionagd. brake set -- release brake  
TROUBLESHOOTING  
------------------------------------------------------------------------------------------------  
----------------Consult dealer  
6. ENGINE SOMETIMES SKIPS AT HIGHER SPEED  
------------------------------------------------------------------------------------------------  
Incorrect ignition timing Carburetor  
--------Readjust carburetor  
maladjusted  
-------------------------------------------------------------------------------Check spark  
Faulty spark plugs  
plug or condition and reset gap*  
7. ENGINE OVERHEATED  
Air intake screen or fins clogged  
-----------------------------------------------------------------------------------Clean  
Fuel mixture too lean  
Intake screen and fins  
Oil level too low or too high  
------------------------------------------------------------------------------------------------  
Improper ignition timing  
Running engine too slow  
----------Readjust carburetor*  
------------------------------------------------------------------------------------------------  
-----------Adjust oil level  
------------------------------------------------------------------------------------------------  
-----------Consult dealer  
------------------------------------------------------------------------------------------------  
8. ENGINE IDLES POORLY  
Carburetor maladjustment  
-----------Run engine faster  
Improper spark plug gap  
(NOTE: Always mow at full throttle setting.)  
9. ENGINE BACKFIRES  
Carburetor maladjustment  
------------------------------------------------------------------------------------------------  
----Readjust carburetor  
------------------------------------------------------------------------------------------------  
10.  
ENGINE RUNS BUT MOWER WON'T  
--Check and re-gap plug*  
MOVE FORWARD  
Drive belt broken or slipping  
Shift linkage cable disconnected  
Transmission shift arm disconnected  
------------------------------------------------------------------------------------------------  
Transmission oil low  
---Readjust carburetor*  
Transmission locks in free wheel position  
Hydrostat oil filter plugged  
Bad transmission  
Gear mating transmission/gearbox disconnected  
------------------------------------------------------------------------------------------------  
-----Replace drive belt  
------------------------------------------------------------------------------------------------  
11.MOWER LOSES POWER OR TRANSMISSION  
---------Reconnect  
OVERHEATS  
------------------------------------------------------------------------------------------------  
Hydrostat transmission oil too low or too high  
Transmission damage  
---Reconnect  
------------------------------------------------------------------------------------------------  
Transmission blowing oil out cap  
----------------------------Add oil  
---------------------------------------------------------------------Put in lock position (see  
pg. 5)  
12.  
ENGINE STALLS WHEN BLADES ARE  
------------------------------------------------------------------------------------------------  
ENGAGED  
Operator not on seat  
------------------------------------------------------------------------------------------------  
--------------Replace filter  
Faulty interlock system  
Bad blade spindle bearing  
-----------------------Consult dealer  
-------------------------------------------------------------------------------Consult dealer  
Deck drive belt not properly routed  
Blades blocked by foreign material  
35  
-----------------------------------------------------------------Add Oil or drain oil as  
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NOTES  
36  
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NOTES  
37  
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OWNER  
INFORMATION  
DIXON INDUSTRIES, INC.  
A BLOUNT International Inc. Co.  
PO BOX 1569  
COFFEYVILLE KS 67337 0945  
316 251 2000  
FAX 316 251 4117  
DATE PURCHASED  
MOWER MODEL NUMBER  
MOWER SERIAL NUMBER  
PURCHASED FROM  
Name  
Ad-  
dress  
DATE OIL CHANGED:  
DATE ENGINE TUNED:  
38  
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The engine exhaust from this product contains chemicals known to  
the State of California to cause cancer, birth defects or other repro-  
ductive harm.  
WARNING  
Dixon® and ZTR® are registered trademarks of Dixon Industries, Inc.  
DIXON INDUSTRIES, INC.  
A BLOUNT International Inc. Co.  
PO BOX 1569  
COFFEYVILLE KS 67337 0945  
316 251 2000  
8000 Series  
8025  
Part No. 13092-0700  
39  
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