Dixon Lawn Mower 8000G Series User Manual

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.  
15  
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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.  
17  
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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).  
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.  
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.  
23  
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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”  
24  
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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.  
26  
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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.  
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  
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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