Dixon Lawn Mower 61935 0603 User Guide

Mod el 2560  
ZTR®  
Mod el Year 2004  
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INDEX  
Page  
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12  
Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14  
Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . .15  
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19  
Operation Instructions. . . . . . . . . . . . . . . . . . . 20-28  
Care & Maintenance. . . . . . . . . . . . . . . . . . . . . .29-38  
Standard Service Parts List. . . . . . . . . . . . . . . . . . . .39  
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . .40-41  
Model 2560  
Part No. 61935-0603  
3
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SAFETY  
RIDING LAWN MOWERS,  
IF IMPROPERLY OPERATED,  
CAN CAUSE SERIOUS INJ URY 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 r ecommended s afet y pr ecaut ions  
and s afe oper at ing pr act ices .  
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 t o obs erve t he following s afet y  
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 mow-  
ing. 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 unclog-  
ging 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 withside  
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 manufacturers 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 attach-  
ments. 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.  
8
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SAFETY  
DO (CONTINUED)  
•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.  
9
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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 seri-  
ously 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  
vis ion.  
10  
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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 contain-  
ers 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 com-  
plete. Do not use a nozzle lock-open device.  
11  
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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.  
12  
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DIXONLIMITEDWARRANTYPOLICY  
Pro Models 1950 ~ 2300 ~ 2560  
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. Home Owner Application: Dixon Model 2560 used only at owner’s primary place of residence  
is warranted for a period of two (2) years from date of purchase. Frame, body panels and  
fendersarewarrantedforthelifeofthemower.  
2. CommercialApplication: Definedasuseotherthan, orinadditionto, mowingatowner’s  
primaryplaceofresidence. Unitsusedincommercialapplicationarewarrantedforaperiodof  
one (1) year from date of purchase or 400 hours of use, whichever comes first.  
3. Warranty applies only to original retail purchaser of new and unusedmowersandaccessories.  
4. 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.  
5. BatteryWarranty: limitedto90daysfromdateofpurchase.  
6. AccessoriesWarranty(grasscatchers, snowblades, covers, etc.):Limitedto90daysfrom  
dateofpurchase.  
7. Warrantydoesnotapplytodamageintransitorincidentsofmisuse, negligence, accidents, or  
alteration. TheuseofpartsorcomponentsotherthanthosesuppliedbyDixonIndustries  
VOIDSALLWARRANTY.  
8. The following items are not covered by this warranty policy:  
(a) Pickupanddeliverychargesfortransportationofmowertoandfromanauthorized  
Dixondealer’splaceofbusiness.  
(b) Routinemaintenanceoradjustments.  
(c) Belts/blades/hydrofilters.  
(d) Engines - All engines used on Dixon ZTR mowers are warranted by each individual  
enginemanufacturer.  
(e) Anycostsorexpenseofprovidingsubstituteequipmentwhilerepairworkisbeing  
performed on a warranted mower.  
9. Thereisnootherexpresswarranty. Impliedwarranties, includingthoseofmerchantabilityand  
fitnessforaparticularpurposearelimitedtothesamedurationoftheexpresswarrantyandto  
theextentpermittedbylawanyandallimpliedwarrantiesareexcluded. Liabilitiesfor  
consequential damages under any and all warranties are excluded.  
13  
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S P ECIFICATIONS  
Model 2 5 6 0  
CHASSIS:  
BODY:  
Folded sheet metal and rectangular tube  
Folded sheet metal  
SEAT:  
Designed for operator comfort with suspension system and  
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 White CE 14 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  
14  
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SEAT ADJUSTMENT INSTRUCTIONS  
Model 2560  
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  
15  
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CONTROLS  
16  
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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.  
move right lever rearward of the left lever.  
To turn on mowers own axis (zero turning radius), stop  
and move one lever to reverse position and the other to  
forward position.  
BRAKING:  
To brake mower, move both levers in direction opposite  
of travel.  
LEFT TURN OPPOSITE  
Note: The pressure required to operate the mower is very light.  
17  
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CONTROLS  
CHOKE CONTROL LEVER:  
Located on control panel to operators right.  
Used to start a cold engine.  
THROTTLE CONTROL LEVER:  
Located on contol panel to operators 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:  
Note:  
Always set parking brake before dismounting. Release  
the parking brake before moving mower.  
Engage parking brake before starting engine.  
HYDRAULIC 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.  
18  
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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.  
19  
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OPERATION INSTRUCTIONS  
The safe and successful operation of the ZTR  
Model 2560 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 with-  
out 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 acci-  
dents.  
20  
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OPERATION INSTRUCTIONS  
BEFORE OPERATING MOWER:  
1 . Read and observe all safety instructions on  
your mower and in the manual.  
2 . Read engine manufacturers operating and  
maintenance instructions.  
3 . Discuss proper maintenance with your  
dealer.  
4 . Check engine oil.  
5 . Check fuel 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).  
21  
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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. The mower blades must be disengaged before the  
engine will start.  
2. The brake lever must be engaged (upward position)  
before engine will start.  
3. 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.  
22  
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OPERATION INSTRUCTIONS  
BLADE DRIVE SWITCH TEST  
(ELECTRIC CLUTCH):  
1. 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.  
2. 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.  
3. If any Safety Check fails, do not operate the mower  
until the system has been checked and repaired by  
an authorized Dixon ZTR dealer.  
23  
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OPERATION INSTRUCTIONS  
STARTING INSTRUCTIONS (cold engine):  
1 . Pull choke control lever up.  
2 . Push throttle control lever to 1/ 2 setting.  
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 down to fully open position.  
5 . 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 2560 will require a slightly longer  
warm up period using partial choke settings.  
24  
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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 the wide open or maxi-  
mum setting for actual operation of the mower deck.  
Note: Model ZTR 2560 may require a 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 ensure adequate lubrication, cooling and  
cut quality of the mower deck.  
DO NOT operate the engine in an  
enclosed area due to the harmful  
exhaus t gas produced.  
CAUTION  
Not e s : 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.  
25  
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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 40-41.  
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 underside of the deck and  
discharge area.  
3 . 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 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. (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) hroughout The Cutting  
Season.  
26  
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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  
Best Cut Heights  
1 - 2”  
2 - 3”  
11/ 2 -3”  
2 - 3”  
3-31/ 2  
Tall Fescue  
Zoysiagrass  
1 - 3”  
27  
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OPERATION INSTRUCTIONS  
TO FREE WHEEL MACHINE  
(UNLOCK TRANSMISSION):  
Always turn off engine before engaging or disengag-  
ing 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,  
between the fuel tank and hydro pumps. To access  
release valves, tilt seat plate forward. Use a 5/ 8”  
wrench to 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 trans-  
mission must be unlocked, and parking brake  
released. The tractor should never be pulled  
at more than two miles per hour or for any  
appreciable distance.  
28  
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CARE AND MAINTENANCE  
CAUTIO N  
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  
29  
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CARE AND MAINTENANCE  
EN GIN E:  
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  
CAUTION  
which is poisonous and corrosive.  
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.  
30  
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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. Blades should be discarded when worn  
excessively.  
3. 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. 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.  
5. 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  
31  
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CARE AND MAINTENANCE  
LUBRICATION:  
1 . Engine: Follow engine manufacturers recommenda-  
tion.  
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.  
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.  
32  
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CARE AND MAINTENANCE  
ELECTRICAL SYSTEMS:  
Keep all connections clean and tight.  
CLEANING THE MOWER:  
Wash mower periodically. Clean above and below the  
deck.  
High pressure washing and alkaline based soaps can  
cause damage to bearings and other parts of the mower.  
After washing your mower, start the engine and engage  
the mower deck for a few minutes to disperse any water  
that may have accumulated in bearings, pulleys or fans.  
Note: Allow mower to cool before washing. If bearings  
are hot, they will draw moisture inside as they dry and  
cause corrosion.  
SERIAL NUMBERS:  
The serial number is located on the frame at the rear of  
the engine.  
W ARRANTY:  
See information on Page 13 of this manual, or refer to  
the Warranty Registration Form in your Owners Pack.  
PARTS AND SERVICE:  
See your Dixon Dealer for replacement parts, warranty or  
service.  
33  
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CARE AND MAINTENANCE  
HYDROSTAT OIL MAINTENANCE PROCEDURE:  
Check the oil level in hydrostatic transmisison oil reser-  
voir after every 25 hours of usage. Clean the oil reser-  
voir 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 transmis-  
sion 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  
34  
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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 en-  
gine to deck drive belt. Roll the engine to deck  
drive belt off the center spindle.  
C. 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.  
D.Position the front caster wheels so they are away  
from the deck (such as the tractor would be  
traveling in reverse).  
E . 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.  
F. 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.  
35  
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CARE AND MAINTENANCE  
36  
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CARE AND MAINTENANCE  
37  
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CARE AND MAINTENANCE  
LEVELING THE DECK:  
1. Set the tire pressure on all 4 tires.  
2. Front casters must be rotated in the direction of  
forward travel.  
3. Move the tractor to a hard level surface.  
4. Put the mower deck in the number 3 deck height  
position.  
5. Rotate the 2 outer spindles so the blades point out-  
board.  
6. Adjust front hangers to level deck side to side, by  
measuring at blade tips.  
7. Rotate all 3 spindles until the blades are fore and aft.  
8. Adjust rear hangers until deck is level to 1/ 4” higher  
in the rear.  
38  
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STANDARD SERVICE PARTS LIST  
MODEL ZTR 2 5 6 0 :  
Blades 60”  
Hi-Lift (Standard)-P/ N 12421  
Low-lift-P/ N 12451  
Gator-P/ N 12508  
Belts  
Engine to Mower Deck Belt-P/ N 1300  
Serpentine Belt 60-P/ N 9758  
Engine to Hydro Belt-P/ N 61778  
Hydrostatic Transmission Filter-P/ N 7252  
KOHLER AIR AND OIL FILTER:  
Refer to engine manufacturers manual for recommenda-  
tions regarding frequency of service required for engine oil  
changes and air filter maintenance.  
Protect your engine investment, use only original equipment  
filters.  
IMP ORTANT:  
Some applications, extreme dirt conditions, or the use of a  
grass catcher may require that the engine used on the  
Model ZTR 2560 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  
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. 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/ spark plug wires  
Carburetor maladjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Ignition switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
3. 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/ regap  
Electronic ignition defective- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Dirty or maladjusted carburetor- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
4. 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  
5. 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  
40  
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TROUBLESHOOTING  
6 . 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  
7. ENGINE RUNS BUT MOWER WON’T MOVE FORWARD  
Drive belt broken or slipping- - - - - - - - - - - - - - - - - - - - - - - - - - - - - replace drive belt  
Shift linkage disconnected- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -reconnect  
Transmission shift arm disconnected- - - - - - - - - - - - - - - - - - - - - - - - - - -reconnect  
Transmission oil low- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - add oil  
Hydrostat oil filter plugged- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -replace filter  
Damaged transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Free wheel feature activated- - - - - - - - - - - - - - - -put in unlock position (see Pg. 28)  
8. 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- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
9. 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. ENGINE IDLES POORLY  
Carburetor maladjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Improper spark plug gap- - - - - - - - - - - - - - - - - - - - - - - - - - check and reset gap*  
12. ENGINE BACKFIRES  
Carburetor maladjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
*see engine manual for engine adjustments  
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 exhaus t fr om t his pr oduct cont ains  
chemicals known t o t he St at e of Califor nia t o caus e  
cancer , bir t h defect s or ot her r epr oduct ive har m.  
WARNING:  
Dixon® and ZTare 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  
Model 2560  
Part No. 61935-0603  
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