Dixon Lawn Mower 13636 0702 User Guide

ZTR®  
OPERATOR’S MANUAL  
2003  
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INDEX  
Page  
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11  
Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . .14  
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-18  
Operation Instructions. . . . . . . . . . . . . . . . . . . 19-26  
Care & Maintenance. . . . . . . . . . . . . . . . . . . . . .27-35  
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 36-37  
Standard Service Parts List. . . . . . . . . . . . . . . . . . . .38  
7500 Series  
Part No. 13636-0702  
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. Always turn  
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 crossing  
roadways.  
•Use extra care when loading or unloading the mower  
into a trailer or truck. Do not ride the mower when  
loading and unloading.  
•Always wear safety goggles or safety glasses with  
side shields when operating mower.  
•Data indicates that operators, age 60 years and  
above, are involved in a large percentage of riding  
mower-related injuries. These operators should  
evaluate their ability to operate the riding mower  
safely enough to protect themselves and others  
from serious injury.  
•Follow the manufacturer’s recommendation for  
wheel weights and counterweights.  
•Maintain or replace safety & instruction labels as  
needed.  
The engine exhaust from this product contains chemicals known to the  
State of California to cause cancer, birth defects or other reproductive  
WARNING:  
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 build-up. 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, as 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 LIMITED WARRANTY POLICY - HYDRO GEAR MODELS  
5000 - 6000 - 7000 Series Mowers  
WARRANTY: Dixon Commercial Warranty is for a period of one (1) year from date of purchase  
or 400 hours of use, whichever occurs first. Mowers used for Homeowner Application (used only  
at owner’s primary place of residence) are warranted for two (2) years from date of purchase.  
DIXON ZTR MOWERS ARE WARRANTED AGAINST DEFECTS IN MATERIALS AND  
WORKMANSHIP AND PROVIDES FOR REPLACEMENT OR REPAIR OF PARTS INCLUDING LABOR  
COSTS. THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS AND LIMITATIONS:  
1.  
Warranty applies only to original retail purchaser of new and unused mowers and  
accessories.  
2.  
All Dixon warranty must be accomplished by authorized Dixon dealers and in  
accordance with Dixon warranty policy and allowances. All warranty claims must be  
approved by Dixon Industries, Inc.  
3.  
4.  
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.  
5.  
6.  
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.  
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/Blades/Hydro filters  
(d) Engines -- All engines used on Dixon ZTR mowers are warranted by each  
individual engine manufacturer.  
(e) Any costs or expense ofproviding 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.  
Copies: Pink/Customer  
Yellow/Dealer  
White/Return to 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  
Deck Size  
S/N  
(Owner's Name)  
(Street Address)  
(City/State/Zip)  
(Dealership Name & Dealer Number)  
(Street Address)  
(City/State/Zip)  
(Owner's Signature)  
(Dealer's Signature)  
DIXON INDUSTRIES, INC.  
A BLOUNT International Inc. Co.  
PO BOX 1569  
COFFEYVILLE KS 67337 0945  
PHONE 620 251 2000  
1-877-CUT-MORE  
FAX 620 251 4117  
12  
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SPECIFICATIONS  
7500 Series  
CHASSIS:  
BODY:  
Folded sheet metal and rectangular tube  
Folded sheet metal  
SEAT:  
Designed for operator comfort with padded back and arm rests.  
Seat is adjustable fore and aft.  
MOWER DECK: Deck is made of 10 GA fabricated welded construction with 7 GA  
reinforcement plates. Three blades combine for a 60" cut width.  
Cut height approximately 1.5" to 5" via 10 position lift handle.  
BLADE DRIVE:  
Electric clutch  
DRIVE SYSTEM: Each rear wheel is independently driven by a HydroGear BDP  
10A pump and a HydroGear HGM-15E hydraulic motor.  
ENGINE:  
25HP Kohler Command, 4-Cycle, V-Configuration, Overhead  
Valve, Air-Cooled, Gasoline, Vertical Shaft, Aluminum Head, and  
Crankcase with Cast Iron Liners, Full Pressure Lubrication/Full  
Flow Filter, Pulse-type Fuel Pump, Fixed Jet Carburetor w/  
Smart-Choke, Electronic Ignition, In-Line Fuel Filter, Dual Element  
Air Cleaner.  
STARTING  
SYSTEM:  
Electric by key switch operation with safety interlocks on parking  
brake and blade drive clutch.  
TIRES:  
Front 13-5.00x6  
Rear 23-9.50x12  
RECOMMENDED Front 12 lbs.  
TIRE PRESSURE: Rear 12 lbs.  
CAPACITIES:  
Fuel - 11 gallons (approx)  
Hydrostat oil system - 4 qt with in-line 40 micron filter  
Hydrostat oil recommendation, refer to page 31  
Engine - 2 qts. SAE 10W30 (with filter)  
DIMENSIONS:  
Width 69-1/2"  
Height 43"  
Length 81”  
Weight 916 lbs.  
Additional information provided in service instructions under the individual component.  
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE  
13  
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SEAT ADJUSTMENT INSTRUCTIONS  
Model 7525  
1.  
Grasp seat slide adjuster and move it into  
adjustment position.  
2.  
3.  
Slide seat forward or backward.  
Release seat slide adjuster.  
Seat Slide Adjuster  
14  
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CONTROLS  
15  
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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.  
16  
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CONTROLS  
CHOKE CONTROL LEVER:  
Located on control panel to operator’s right.  
Used to start a cold engine.  
THROTTLE CONTROL LEVER:  
Located on contol panel to operator’s right.  
Controls engine speed, slow to maximum.  
While moving, throttle control should be set to MAXIMUM  
or wide open setting to insure adequate cooling of the engine  
& to maintain mower deck blade speed.  
PARKING BRAKE:  
The hand operated parking brake is located on the left of the  
mower. It is designed to hold the mower from moving and is  
not intended for use in stopping the mower while it is in motion.  
To engage brake: pull lever upward.  
To disengage brake: push lever downward.  
Note: Always set parking brake before dismounting. Release  
the parking brake before moving mower.  
Note: Engage parking brake before starting engine.  
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.  
17  
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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 the  
operator.  
Controls the cutting height.  
Ten positions of adjustment.  
Depress trigger and move lever  
forward to lower deck.  
Depress trigger and pull lever back  
to raise deck.  
Note: Always use high position for  
transport.  
18  
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OPERATION INSTRUCTIONS  
The safe and successful operation of the ZTR 7500  
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.  
Sound judgement by the owner will prevent accidents.  
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.  
8.  
Discuss proper maintenance with your dealer.  
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).  
19  
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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.  
The mower blades must be disengaged before  
the engine will start.  
The brake lever must be engaged (upward  
position) before engine will start.  
The engine will stop if the mower blade clutch  
is engaged when the operator leaves the  
driver's seat.  
4.  
This unit is equipped with a mechanical  
control lever lockout. The brake lever must  
be disengaged before control levers will move  
forward.  
20  
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OPERATION INSTRUCTIONS  
BLADE DRIVE SWITCH TEST (ELECTRIC CLUTCH):  
1.  
2,  
3.  
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.  
In a safe area, away from bystandards, 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.  
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 (cold engine):  
1.  
2.  
3.  
Pull choke control lever up.  
Push throttle control lever to 1/2 setting.  
Insert ignition key and turn to “START” position.  
When engine starts, release ignition key. Key  
will return to “RUN” position.  
4.  
5.  
Once engine starts to warm up, slowly push  
choke control lever down to fully closed position.  
Move throttle control lever to the wide open or  
maximum setting for actual operation of the  
mower deck.  
6.  
Engine must be operated at wide open or  
maximum setting to ensure adequate lubrication,  
cooling and cut quality of the mower deck.  
Note: Model ZTR 7525 will require a slightly longer  
warm up period using partial choke settings.  
22  
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OPERATION INSTRUCTIONS  
STARTING INSTRUCTIONS(engine has been operated):  
1.  
2.  
Move throttle control lever to 1/4 to 1/2 setting.  
Insert ignition key and turn to “START” position.  
When engine starts, release ignition key. Key  
will return to “RUN” position.  
3.  
4.  
Move throttle control lever to the wide open or  
maximum setting for actual operation of the  
mower deck.  
Note: Model ZTR 7525 may require a partial  
choke setting to start even if the engine  
has been operated for a period of time.  
Engine must be operated at wide open or  
maximum setting to ensure adequate lubrication,  
cooling and cut quality of the mower deck.  
DO NOT operate the engine in an  
CAUTION  
enclosed area due to the harmful  
exhaust gas produced.  
Notes: On initial operation, set throttle at slow speed.  
Engine cannot be restarted when blades are  
engaged.  
Safety switches stop engine when operator  
leaves seat while mower blade is engaged.  
Always turn engine off when leaving mower.  
23  
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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  
on Page 36-37.  
CAUTION Be sure that deflector is properly installed  
on the discharge chute.  
1.  
2.  
Set engine speed control to the wide open or full  
setting.  
Do Not Attempt To Cut Grass When It Is Wet.  
Wet grass will clog the underside of the deck  
and discharge area.  
3.  
4.  
If the grass is tall, place the mower deck cut height  
lever inthe top or second notch. “Initially” overlap  
cutting swaths instead of taking a full swathwith  
each pass. Some applications may require a  
second cutting.  
Keep The Underside Of The Mower Deck Clean.  
Frequent removal of dried grass and dirt will allow  
the clippings to discharge correctly. (Never attempt  
to clean or service deck with engine running and/or  
PTO engaged. This safety precaution must be  
observed or serious injury could occur.)  
5.  
Maintain Sharp Blade(s) Throughout The Cutting  
Season.  
24  
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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.  
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 on adequate  
moisture conditions and normal thatch build-up 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  
Bermudagrass  
Bluegrass  
Buffalograss  
Ryegrass  
Tall Fescue  
Zoysiagrass  
Best Cut Heights  
1 - 2”  
2 - 3”  
11/2 -3”  
2 - 3”  
3-31/2  
1 - 3”  
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 behind the seat,  
between the fuel tank and hydro pumps. Use a 5/8”  
wrench and insert through the slots on the top side of the  
seat plate and rotate bolt counter-clockwise two full turns  
to disengage pump. Repeat procedure for opposite pump.  
To engage, rotate each pump bolt clockwise until bolt is  
snug.  
Note: Before pushing or towing tractor, the transmis-  
sion must be unlocked, and parking brake re-  
leased. The tractor should never be pulled at  
more than two miles per hour or for any appre-  
ciable distance.  
26  
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CARE AND MAINTENANCE  
CAUTION  
Before performing any maintenance, turn off engine,  
allow to cool, remove key & 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 crankcase oil level................................................................................before each use  
Clean grass from hydrostat fans & cooling 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  
Check mower blades for sharpness.................................................................every 10 hours  
Clean air filter element.........................................................................................every 25 hours  
Check hydrostatic transmission fluid..................................................................every 25 hours  
Check all belts(20 hours break-in).....................................................................every 50 hours  
Grease all zerks.....................................................................................................every 50 hours  
Service air filter element....................................................................................every 100 hours  
Change engine crankcase oil.........................................(5 hours break-in)every 100 hours  
Change engine oil filter......................................................................................every 200 hours  
Change hydrostat oil & oil filter.................................(100 hours break-in)every 500 hours  
Replace air filter element.............................................................annually or every 500 hours  
Check spark plugs.........................................................................annually or 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  
-
-
12 lbs.  
12 lbs.  
Lug nuts or lug bolts should be checked regularly for tightness.  
28  
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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  
V-BELTS:  
There are 3 v-belts on your Dixon Zero Turning Radius Mower.  
They should be checked every 50 hours. Replace any belts found  
to be in poor condition.  
29  
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CARE AND MAINTENANCE  
LUBRICATION:  
1.  
Engine: Follow engine manufacturer’s  
recommendation.  
2.  
Deck spindles: Lubricate with 3 “shots” only,  
every 100 hours.  
HYDROSTATIC TRANSMISSIONS:  
Before each use, check to be sure that the cooling fins  
and fans of the pumps and wheelmotors are clean.  
Excessive accumulation of oil, dirt, or trash may cause  
the transmissions to overheat. NEVER WASH ACROSS  
TOP OF RESERVOIR WITH WATER OR STEAM. Fill  
reservoir as required per the maintenance schedule  
listed in this book.  
30  
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CARE AND MAINTENANCE  
HYDROSTAT OIL MAINTENANCE PROCEDURE:  
Check the oil level in hydrostatic transmisison 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 a new OEM filter (P/N 7252) 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  
PROCEDURE FOR RAISING AND LOWERING  
THE DECK FOR SERVICING:  
A.  
Move cut height adjustment lever to lowest  
position.  
B.  
Flip up the foot deck to allow access to the  
engine to deck drive belt. Roll the engine to deck  
drive belt off the center spindle. Hook the engine  
to deck drive belt onto the bolt protruding out of  
the top of the foot deck support angle.  
C.  
D.  
E.  
F.  
Lift the rear corner of the deck and remove 1/2”  
x 1-1/2” clevis pin from lift link/eye bolt. Repeat  
for the other side.  
Position the front caster wheels so they are  
away from the deck (such as the tractor would  
be traveling in reverse).  
Attach a hoist to the deck lift bolt. Lift the nose of  
the deck until the deck is standing vertical and  
the deck latch engages.  
Reverse procedure for lowering deck.  
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  
suspension). This will prevent the deck from falling  
down when servicing the underside of the mower deck.  
32  
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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). Place a 2x4 board under  
all four corners of the deck shell, just inside the  
anti-scalping wheels. Lower the deck down onto  
the boards. The deck must rest on the boards,  
not on the anti-scalping wheels. Adjust the deck  
hangers longer or shorter until the deck “just”  
comes off of the boards in front. Raise the rear  
1/4” above the boards. Remove the boards and  
verify that 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 if the fender skirts  
are removed.)  
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CARE AND MAINTENANCE  
34  
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MOWER SHOWN IN SERVICING POSITION  
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TROUBLESHOOTING  
1.  
ENGINE WON’T TURN OVER  
Mower blades engaged- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -disengage blades  
Blown fuse- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -replace fuse  
Dead battery- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -charge or replace  
Solenoid- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Ignition switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Starter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Parking brake not set - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - engage parking brake  
2.  
3.  
ENGINE WILL TURN OVER BUT WON’T START  
No fuel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -refuel and/or clean or replace fuel filters  
Over or under choked- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - adjust choke  
Spark plug not firing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -check spark plug wires  
Carburetor maladjustment- - - - - - - - - - - - - - - - - - - - - - -- -- readjust carburetor/consult dealer  
Ignition switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - readjust carburetor/consult dealer  
HARD TO START ENGINE  
No fuel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -refuel and/or clean or replace fuel filters  
Fuel line clogged- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - clean fuel line and check fuel filter  
Faulty fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Spark plug wire loose or grounded - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -check spark plug wires  
Spark plug(s) faulty or improperly gapped- - - - - - - - - - - - - - - - - - - - - - - - - - - - - check spark plug  
Electronic ignition defective- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 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- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - clean or replace fuel line  
Fuel tank vent plugged- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - check vent and clean  
Faulty fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -replace/consult dealer  
Maladjusted carburetor- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
ENGINE KNOCKS  
Low oil level- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - check and add oil  
Fuel octane too low- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -replace with higher octane gasoline  
Over heated engine- - - - - - - - - - - - - - - - - - - - - - shut off engine and allow to cool/consult dealer  
*see engine manual for engine adjustments  
36  
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TROUBLESHOOTING  
6.  
7.  
ENGINE OVERHEATED  
Air intake screen or fins clogged- - - - - - - - - - - - - - - - - - - - - - - - - - clean intake screen and fins  
Oil level too low or too high- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - adjust oil level  
Running engine too slow- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - run engine faster  
Fuel mixture too lean- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Improper ignition timing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - --consult dealer  
ENGINE RUNS BUT MOWER WON’T MOVE FORWARD  
Drive belt broken or slipping- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - replace drive belt  
Shift linkage cable disconnected- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - reconnect  
Transmission shift arm disconnected- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -reconnect  
Transmission oil low- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -add oil  
Hydrostat oil filter plugged- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - replace filter  
Damaged transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Gear mating transmission/gearbox disconnected- - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Free wheel feature activated- - - - - - - - - - - - - - - - - - - - - - - -put in unlock position (see Pg. 26)  
8.  
9.  
MOWER LOSES POWER OR TRANSMISSION OVERHEATS  
Hydrostat transmission oil too low or high- - - - - - - - - - - - - - - - - - - - - add oil or drain as needed  
Transmission damage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Transmission blowing oil out cap- - - - - - - - - - - - - - - - - - - - - - - -overfilled or water contaminated  
ENGINE STALLS WHEN BLADES ARE ENGAGED  
Operator not on seat- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - sit on seat  
Faulty interlock system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Damaged blade spindle bearing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Deck drive belt not properly routed- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- reroute  
Blades blocked by foreign material- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - clean under deck  
10.  
ENGINE SOMETIMES SKIPS AT HIGHER SPEEDS  
Incorrect ignition timing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Carburetor maladjusted- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Faulty spark plugs- - - - - - - - - - - - - - - - - - - - - - - - -check spark plug or condition and reset gap*  
11.  
12.  
ENGINE IDLES POORLY  
Carburetor maladjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consultdealer  
Improper spark plug gap- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -check and reset gap*  
ENGINE BACKFIRES  
Carburetor maladjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consultdealer  
*see engine manual for engine adjustments  
37  
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STANDARD SERVICE PARTS LIST  
MODEL ZTR 7525:  
Blades 60” Hi-Lift:  
Blades 60” Lo-Lift:  
Engine to Mower Deck Belt:  
Serpentine Belt 60”:  
Engine to Hydro Belt:  
P/N 60295  
P/N 60293  
P/N 61515  
P/N 61512  
P/N 61778  
P/N 7252  
Hydrostatic Transmission Filter:  
KOHLER AIR AND OIL FILTER PART NUMBERS:  
Refer to engine manufacturer’s manual for recom-  
mendations regarding frequency of service required  
for engine oil changes and air filter maintenance.  
Protect your engine investment, use only original  
equipment filters.  
MODEL ZTR 7525 (25HP):  
Air Filter & Pre-Cleaner Kit  
Engine Oil Filter  
78002  
78006  
IMPORTANT:  
Some applications, extreme dirt conditions, or the use  
of a grass catcher may require that the engine used on  
the Model ZTR 7525 be fitted with an optional Kohler  
fresh air filter system. Check with your engine service  
center for availability.  
38  
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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:  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
39  
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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  
7500 Series  
Model 7525  
Part No. 13636-0702  
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