Operator's Manual
7000 SERIES
ZTR® MOWERS
2000
1Page
IMPORTANT - READ CAREFULLY
The Dixon®ZTR®Mower is both easy and fun to operate. However,
any power mower must be operated properly to be safe. It is not a toy
or a recreational vehicle. Before you start to use the mower, read the
operator's manual carefully and become completely familiar with the
controls.
The information in this operator's manual applies to all Dixon
®
ZTR®7000 Series Commercial Mowers. Your Dixon dealer will gladly
answer any questions.
See your dealer for warranty service, parts and repairs.
DIXON INDUSTRIES, INC.
A BLOUNT International Inc. Co.
PO BOX 1569
COFFEYVILLE KS 67337 0945
316 251 2000
2Page
INDEX
SAFETY..........................................................Pages 4-9
WARRANTY POLICY .....................................Page 10
SPECIFICATIONS ..........................................Page 11
SEAT ADJUSTMENT.....................................Page 12
CONTROLS....................................................Pages 13-16
OPERATION INSTRUCTIONS.......................Pages 17-22
CARE AND MAINTENANCE .......................... Pages 23-33
STANDARD SERVICE PARTS LIST .............Page 34
TROUBLESHOOTING ...................................Pages 35-36
7000 Series
Part No. 13091-0500
3Page
SAFETY
RIDING LAWNMOWERS, IF IMPROPERLY OPERATED,
CAN CAUSE SERIOUS INJURY OR DEATH
The most common causes of injury to the operator or bystander...
BLADE CONTACT TIP-OVER
BACK-OVERRUN-OVER
...read and understand this manual to prevent injuries.
Page 4
SAFETY
Safety Alert Symbol
When you see this symbol,
BE ALERT to the potential for injury.
Follow recommended safety precautions and safe
operating practices.
Danger
indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury.
Warning
indicates a potentially hazardous situation
which, if not avoided, could result in death
or serious injury.
Caution
indicates a potentially hazardous situation
which, if not avoided, may result in minor or
moderate injury. It may also be used to alert
against unsafe practices.
Page 5
SAFETY
This cutting mower is capable of amputating hands & feet,
and throwing objects.
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.
• Turn off blades when not mowing.
• Stop engine before removing grass catcher or unclogging chute.
• Mow only in daylight or good artificial light.
• Do not operate the mower while under the influence of alcohol or drugs.
• Watch for traffic when operating near or crossing roadways.
• Use extra care when loading or unloading the mower into a trailer or truck. Do not ride the
mower when loading & unloading.
• Always wear safety goggles or safety glasses with side shields when operating mower.
• Data indicates that operators, age 60 years and above, are involved in a large percentage
of riding mower-related injuries. These operators should evaluate their ability to operate
the riding mower safely enough to protect themselves and others from serious injury.
• Follow the manufacturer's recommendation for wheel weights or counterweights.
• Maintain or replace safety and instruction labels, as necessary.
Page 6
W ARNING:
The engine exhaust from this product contains chemicals known to the
California to cause cancer, birth defects or other reproductive harm.
State of
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.
SAFETY
If you cannot back up the slope or if you feel uneasy on 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 mow it!
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.
Page 7
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.
Page 8
SAFETY
SERVICE:
• Use extra care in handling gasoline and other fuels. They are flammable and vapors are
explosive.
Use only an approved container.
Never remove gas cap or add fuel with the engine running. Allow engine to cool before
refueling. Do not smoke.
Never refuel the mower indoors.
Never store the mower or fuel container inside a building where there is an open flame.
If fuel is spilled on clothing, change clothing 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 gas-powered equipment from the truck or trailer and refuel
it on the ground. If this is not possible, then refuel such equipment on a trailer with a
portable container, rather than from a gasoline dispenser nozzle.
If a gasoline dispenser nozzle must be used, keep the nozzle in contact with the rim
of the fuel tank or container opening at all times until fueling is complete. Do not use a
nozzle lock-open device.
• Never run a mower inside a closed area. The exhaust fumes are toxic.
• Keep nuts and bolts tight, especially blade attachment bolts, and keep equipment in good
condition.
• Never tamper with safety devices. Check their proper operation regularly.
• Keep mower free of grass, leaves, or other debris buildup. Clean up oil or fuel spillage. Allow
mower to cool before storing.
• Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting.
• Never make adjustments or repairs with the engine running.
• Grass catcher components are subject to wear, damage, and deterioration, which could
expose moving parts or allow objects to be thrown. Frequently check components and
replace with original 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.
Page 9
DIXON INDUSTRIES, INC.
a BLOUNT company
AIRPORT INDUSTRIAL PARK
PO BOX 1569
COFFEYVILLE KS 67337 0945
316 251 2000
FAX 316 251 4117
DIXON LIMITED W ARRANTY POLICY - COMMERCIAL MODELS
Models 6000 & 7000
WARRANTY: Home Owner Application: This Dixon Warranty term is for a period of two (2) years from
date of purchase. Commercial Application: Dixon mowers used for commercial application are warranted
for 1 year from the date of purchase. 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 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. 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) Routine maintenance or adjustments.
(c) Belts/cutting blades/HydroGear filters.
(d) Engines -- All engines used on Dixon ZTR mowers are warranted by each individual engine
manufacturer.
(e) Any costs or expense of providing substitute equipment while repair work is being performed on a
warranted mower.
7. There is no other express warranty. Implied warranties, including those of merchantability and fitness for
a particular purpose, are limited to the same duration of the express warranty, and to the extent permitted
by law any and all implied warranties are excluded. Liabilities for consequential damages under any and
all warranties are excluded.
Page 10
SPECIFICATIONS
7000 Series
CHASSIS: 11 GA - rectangular tube
BODY: Folded sheet metal.
SEAT: Designed for operator comfort with padded back and arm rests. Seat is
adjustable fore and aft.
MOWER DECK: 2 Decks are available. Both decks are made of 10 GA fabricated welded
construction with 7 GA reinforcement plate. 3 blades combine for either
a 52" or 60" cut width. Cut height approximately 1.5" to 5" via 7 position
lift handle.
BLADE DRIVE: Electric clutch
DRIVE SYSTEM: Each rear wheel is independently driven by a HydroGear BDU-10L
Series 70 hydrostatic transmission. The hydrostatic transmissions, in
turn, power a fully enclosed HydroGear gearbox.
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 tank - 3 quart with in-line 40 micron filter
Hydrostat oil recommendation, refer to page 36
Engine - 2 qts. SAE 10W30 (with filter)
DIMENSIONS: Width 61"(52" Deck), 69-1/2"(60" Deck)
Height 43"
Length 81" (52” Deck), 81” (60” Deck)
Weight 915 lbs.(48" Deck), 916 lbs.(60" Deck)
NOTE: Additional information provided in service instructions under the individual
component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
Page 11
SEAT ADJUSTMENT
INSTRUCTIONS
Model 7025
1. Grasp seat slide adjuster and move it into adjustment
position.
2. Slide seat forward or backward.
3. Release seat slide adjuster.
Page 12
CONTROLS
Steering Control Levers
Blade Clutch Switch
Ignition Key
Throttle
Cut Height Adjustment Lever
Choke
Parking Brake Lever
Cut Height Stop Pin
Page 13
P ARKING BRAKE:
The parking brake is designed to hold the mower from
moving and is not intended for use in stopping the mower
while it is in motion.
CONTROLS
CAUTION
Engage parking brake before starting engine
TO SET PARKING BRAKE:
The hand operated parking brake is located at left hand side of mower.
To engage brake, pull upward.
To release brake, move lever downward.
NOTE: Always set parking brake before dismounting.
Release parking brake before moving mower.
HYDRO-GEAR DRIVE SYSTEM:
Allows the mower to turn on its own axis (zero turning radius).
Page 14
Each lever controls one side of the mower.
NOTE: The pressure required to operate the mower is very light.
TO GO FORWARD:
From neutral position, gently push both drive levers forward.
To increase speed, move levers farther forward.
TO GO BACKWARD:
From neutral position, gently pull both drive levers toward you.
CONTROLS
TURNING:
Turning is controlled by moving one drive lever slightly forward or rearward of
the other.
To turn left, move left lever rearward of the right lever.
To turn "square corners" move lever of desired direction to neutral.
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, release levers
to neutral, set parking brake. Park only on level surfaces.
CHOKE CONTROL LEVER:
Located on control panel to operator's right.
Used to start a cold engine.
THROTTLE CONTROL LEVER:
Located on control panel to operator's right.
Controls engine speed, slow to maximum.
While mowing, throttle control should be set to the MAXIMUM or wide open
setting to insure adequate cooling of the engine and to maintain mower deck
blade speed.
Page 15
BLADE DRIVE:
Located on control panel, on operator's right.
To engage blades:
To disengage blades:
CONTROLS
Pull up on the switch.
Push down.
MOWER DECK CUT HEIGHT LIFT LEVER:
Located to the right and front of operator.
Controls the cutting height.
Seven positions of adjustment.
Lift lever and place stop pin in hole corresponding
to the desired height. Let lever rest on the pin
stop.
NOTE: Always use high position for transport.
Page 16
OPERATION INSTRUCTIONS
The safe and successful operation of the Model ZTR 7000 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 engine manufacturer's operating and maintenance
instructions.
2. Discuss proper maintenance with your dealer .
3. Read and observe all safety instructions on your mower and in
the manual.
4. Check engine oil.
5. Check gas cap to be sure it is in place.
6. Be sure parking brake is on.
7. Mower blade drive is off.
8. Know how to stop engine. (Turn key to of f position)
Page 17
OPERATION INSTRUCTIONS
TESTING OF SAFETY INTERLOCK SYSTEMS:
Do not operate mower if safety switches are not operating properly.
Your Zero Turning Radius Mower is equipped with switches interlocked for your
safety.
1. The mower blades must be disengaged before the engine will start.
2. The steering control levers must be in neutral "OUT" position before the
engine will start.
3. The engine will stop if the mower blade clutch is engaged when the
operator leaves the driver's seat.
4. The engine will stop if the steering control levers are not in the neutral
"OUT" position when the operator leaves the driver's seat.
5. The engine will stop if the brake is "SET" and the steering control levers
are moved to the "IN" position.
6. The engine will stop if the brake is "SET" and the mower blade clutch is
engaged.
BLADE DRIVE SWITCH TEST : (Electric Clutch)
a. With the electric blade drive switch turned on
and the parking brake in "ON" position,
engine should not turn over or attempt to
start when key switch is moved to the start
position.
b. In a SAFE AREA away from bystanders, start
the engine, place throttle setting at maximum
or full. Engage the blade drive through the
electric clutch switch. Raise weight slightly
off of seat. Engine should stop.
c. If any Safety Check fails, do not operate the
mower until the system has been checked and
repaired by an Authorized Dixon ZTR Dealer.
Page 18
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 lever down to
the fully closed 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 insure
adequate lubrication, cooling and cut quality of the mower deck.
NOTE: Model ZTR 7025 will
require a slightly longer
warm up period using
partial choke settings.
19Page
OPERATION INSTRUCTIONS
STARTING INSTRUCTIONS: Engine has been operated.
1. Move throttle control lever to 1/4 to 1/2 setting.
2. Insert ignition key and turn to "Start" position. When engine starts,
release ignition key. Key will return to "Run" position.
3. Move throttle control lever to wide open or maximum setting for actual
operation of the mower deck.
NOTE: Model ZTR 7000 Series may require partial choke setting to start
even if the engine has been operated for a period of time.
4. Engine must be operated at wide open or maximum setting to insure
adequate lubrication, cooling and cut quality of the mower deck.
CAUTION
NOTE: On initial operation, set throttle at slow speed.
DO NOT operate the engine in an enclosed area due to the
harmful exhaust gas produced.
Engine cannot be restarted when blade is engaged.
Safety switches stop engine when operator leaves seat while
mower blade is engaged.
Always turn engine off when leaving mower.
Page 20
OPERATION INSTRUCTIONS
In order to achieve optimum cutting performance, please read and follow the tips listed below.
Additional information can be found in the troubleshooting guide beginning on page 35.
CAUTION
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 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.
4. Keep The Underside Of The Mower Deck Clean. Frequent removal of dried grass and dirt will
allow the clippings to discharge correctly.
5. Maintain Sharp Blade(s) Throughout The Cutting Season.
Be sure that deflector is properly installed on the
discharge chute.
GRASS HEIGHT SUGGESTIONS:
Correct mowing height can reduce weeds and disease by 50% to 80%
The following grass cut heights are based on adequate moisture conditions and normal thatch
buildup in a healthy lawn. Some locations and applications may require slightly different cut
heights. If in doubt, consult your local lawn professional for assistance.
Grass Types: Best Cut Heights:
Zoysia 2" - 2 1/2"
Blue Grass 1 1/2" - 3"
Fescue Blends 1 1/2" - 3"
St. Augustine (Mid South) 1 1/2" - 2"
St. Augustine (Deep South) 3" - 4"
Tifton Bermuda 1 1/2"
Centipede 1 1/2" - 2"
Common Bermuda 1 1/2" - 2"
Bahia/Argentina/Pensacola 2"
Page 21
OPERATION INSTRUCTIONS
TO FREE WHEEL MACHINE: UNLOCK TRANSMISSION
The transmission release levers are located on each side of the
mower behind the rear drive axles and below the engine mounting
plate. Lift the levers slightly, push them forward and then down to
release the transmission for free wheeling.
To engage the transmissions lift the levers slightly, pull them to the
rear and them down.
NOTE: The tractor should never be pulled at more than 2 miles per
hours or for any appreciable distance.
Page 22
CARE AND MAINTENANCE
CAUTION
Before performing any maintenance, turn off engine, allow to cool, remove key
and disconnect spark plugs. Use extreme care when working on machinery.
Do not wear watch or jewelry. Do not wear loose fitting clothes, and observe
all common safety practices with tools.
MAINTENANCE SCHEDULE
Check drive belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(20 hours break-in)
Check crankcase oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . before each use
Clean grass from Hydrostat fans and cooling fans . . . . . . . . . . . . . . . before each use
Check air intake screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . after each use
Clean grass under deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . after each use
Check tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . every 10 hours
Check battery fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . every 10 hours
Sharpen mower blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . every 10 hours
Clean air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . every 25 hours
Check hydrostatic transmission fluid . . . . . . . . . . . . . . . . . . . . . . . every 25 hours
Service air filter element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . every 100 hours
Change engine crankcase oil . . . . . . . . . . . . . . . . . . . . . . . . . . every 100 hours
(5 hours break-in)
Change engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . every 200 hours
Change hydrostat oil & oil filter . . . . . . . . . . . . . . . . . . . . . . . . . every 500 hours
(100 hours break-in)
Replace air filter element . . . . . . . . . . . . . . . . . . . . . . annually or every 500 hours
Check spark plugs . . . . . . . . . . . . . . . . . . . . . . . . annually or every 500 hours
Service battery. . . . . . . . . . . . . . . . . . . . . . . . . . . annually or every 500 hours
every 50 hours
Page 23
ENGINE:
CARE AND MAINTENANCE
For complete maintenance and operating information of the engine, please refer to the
maintenance instructions furnished by the engine manufaturer and included in your Zero
Turn Radius Mower information packet.
Note: Air intake screen must be kept clean. If plugged, engine may be seriously damaged
by over heating.
CAUTION
Battery electrolyte is a poisonous and corrosive sulfuric
acid solution. Avoid spilling on skin, eyes and clothing.
BATTERY:
Check the fluid in the battery at frequent intervals.
Keep fluid level above the plates in each cell, using distilled water.
OFF SEASON BATTERY STORAGE:
Identify each cable so cables can be reconnected to correct terminals.
Disconnect cables from terminals.
ALWAYS disconnect ground cable first and reconnect last.
Charge battery.
DO NOT remove battery from mower.
Clean top of battery and terminals with baking soda and water.
TIRES:
Page 24
Correct tire pressure is essential for efficient operation of the mower. Check tire
pressure periodically. Inflate tires to the pressure listed below.
Front tires - 12 lbs.
Rear tires - 12 lbs.
Lug nuts or lug bolts should be checked regularly for tightness.
CARE AND MAINTENANCE
Stop engine, remove ignition key and spark plugs for safety. Wear
CAUTION
MOWER BLADES:
Check sharpness of mower blades after every 10 hours of operation. To sharpen
blades, proceed as follows.
A. Remove bolt, lock washer, and cup washer mounting blade on shaft.
B. Blades should be discarded when worn excessively.
C. Sharpen blade with a hand file, electric grinder or blade sharpener. Wear gloves
D. Check balance of blade by positioning the blade on a nail or blade balance
heavy, thick gloves when holding onto cutter blade, avoid the sharp
edge of the blade.
Remove blade.
and eye protection when sharpening. Grind blade at original 25 degree bevel.
pedestal. Grind the blade on the end that is heavier until both sides balance.
E. Install blade, cup washer, lock washer and bolt.
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. All belts
are equipped with spring loaded belt tighteners and do not require tightening
adjustments.
Make sure to tighten bolt to 60 ft. lbs.
New Blade
25 degrees
When notch starts,
discard blade
DANGEROUS!
DO NOT USE
BLADE IN THIS
CONDITION!
Page 25
CARE AND MAINTENANCE
LUBRICATION:
A. Engine: Follow engine manufacturer's recommendation.
B. Deck spindles: Lubriacte with 3 "shots" only, every 100 hours.
C. Hydrostatic transmission and filter (follow instructions listed below).
Dirt or water in oil can ruin the hydrostatic transmissions.
CHECKING & REPLENISHING OIL IN HYDROSTATIC
TRANSMISSION
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 on the dipstick.
The proper oil level should register between the marked hole on the dipstick and the end of the
dipstick. Replenish as needed with 20W-50 Motor Oil. DO NOT OVERFILL. When checking
the oil level, be very careful to keep the reservoir clean.
Change the oil in the reservoir and hydrostat transmission oil filter after the first 100 hours of
use. Then every 500 hours after that. Remove the filter and be sure all oil has drained from the
reservoir. Replace with new filter and 20W-50 Mobil Super II.
Oil Reservoir Cap
Dipstick
Fuel Cap
Please dispose of used oil at proper collection centers - protect your environment
Page 26
CARE AND MAINTENANCE
PARKING BRAKE ADJUSTMENT
With the brake handle in the release position, remove the cotter pin from the castle nut. Insert
a 0.010 feeler gauge between the brake disc and the brake puck. Tighten the castle nut with
the feeler gauge inserted until the gauge fits snugly between the disc and puck. The gap
should not be so tight that the feeler gauge cannot be reinserted after removal. Back the
castle nut to the closest pin hole and reinsert the cotter pin. Repeat for other side. See
picture below.
.010 between Brake Disk and Brake Puck
Castle Nut
Actuating Lever
Brake Linkage Spring
Stop
Page 27
CARE AND MAINTENANCE
HYDROSTATIC TRANSMISSIONS:
Before each use, check to be sure that the cooling fins of the hydrostatic transmissions
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.
HYDROSTAT DRIVE BELT REPLACEMENT PROCEDURE:
(The hydrostatic drive is equipped with a manual belt take-up).
A. Remove the 3/8" locknut, washers, and rubber spacer from the rear of the assembly.
B. Allow the idler arm/pulley to swing forward towards the fornt of the mower. Remove old
belt if required. Replace with new belt.
C. With the belt in place on all pulleys, reinsert the rubber spacer, washers, and 3/8"
locknut. Tighten 3/8" locknut until rubber spacer is deflected approximately 1/8" to 3/16".
Make sure belt is not too tight. Belt deflection or movement should be approximately
1/4" to1/2" when measured at mid-point between hydro and idler pulley.
Page 28
CARE AND MAINTENANCE
STEERING CONTROL ADJUSTMENTS
A. To Adjust Neutral:
1. Remove the fender skirts from each side of the machine.
2. Block up the unit so that the Drive Wheels are off the ground.
3. Start the engine and run at a fast idle with the Steering control levers in the "out"
position.
4. Loosen the locknuts tightened against the rod end ball joints in the Upper Linkage
Assembly.
NOTE: One of these is a left hand nut and will have to be turned backwards.
5. Adjust the Neutral Position by turning the rod in the upper linkage until the wheel stops
turning.
6. Retighten the nuts on the Upper Linkage Assembly and check to see that the drive
wheel is still not turning.
7. Repeat steps 1-6 for the other side.
8. Shut off engine before removing the blocks.
B. To Adjust "IN" Position of the Steering Controls:
1. Remove the two front bolts, lockwashers, and washers which hold the fender cap.
2. Pull the boot from the hole in the fender cap, exposing the cast iron lever.
3. Using a 5/32" Allen wrench, turn the setscrew to adjust the stop.
4. Replace the boot into the hole in the fender cap.
5. Replace the two front bolts, lockwashers and washers.
C. To Align Handles:
Sit on the seat and push the control levers full forward and full backward. If the ends do not
match, the handles may be adjusted as follows:
1. Locate setscrew stops in the steering control lever base which stop the lever in each
direction.
NOTE: The one at the rear is the stop for FWD and the one in the front is the stop for
REV.
2. Adjust setscrew stops so that handles line up together when shifted full forward and full
reverse.
Page 29
CARE AND MAINTENANCE
STEERING CONTROL ADJUSTMENTS (continued):
D. Adjusting for Straight Forward Tracking:
In large open area, actuate the control handles into the full forward position. If the mower veers in
either direction (left or right) some adjustment is necessary.
1. If the mower veers to the right, then the right hydrostat needs to be sped up. If the
mower veers to the left, then the left hydrostat needs to be sped up.
2. Stop the machine and shut off the engine.
3. Slightly loosen the bolt at the lower end of the upper linkage assembly on the side that
is slower. Using a 1/8" Allen wrench turn the setscrew 1/4 turn in. It may take several
test drives to get the mower to track straight forward.
4. Once the tracking is to the operator's liking, completely tighten the bolt on the control
linkage assembly that was loosenedearlier.
5. Recheck to make sure neutral adjust has not been effected, see procedure A.
Inward Stop Setscrew
Reverse Stop
Setscrew
Forward Tracking
Upper linkage Assembly
RH Locknut
Steering Control Lever
Access Hole
Forward Stop
Setscrew
Rod End Ball Joint
LH Locknut
Turn this rod to
Adjust Neutral
Setscrew used to adjust
Page 30
Loosen Bolt on Linkage
CARE AND MAINTENANCE
LEVELING THE DECK
A. Set the tire pressure on all four tires.
B. 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 of the anti-scalping
wheels. Lower the deck down onto the boards. The deck must rest on the
boards, not the anti-scalping sheels. Adjust the deck hangers longer or shorter
until the deck "just" comes off of 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 in the fender skirts are removed).
Rear Deck Hanger
(one each side)
Front Deck Hanger
(one each side)
2 x 4 board, one each corner, just inside
of anti-scalping wheel
Page 31
CARE AND MAINTENANCE
PROCEDURE FOR RAISING AND LOWERING THE DECK
FOR SERVICING
RAISING THE DECK:
A. Remove cut height adjustment pin and completely lower the cut height adjustment
lever. Re-insert the cut height adjustment pin into the 3-1/2" cut height position (this
will lock the cut height adjustment lever into the lowest position.
B. Flip up the foot deck to allow access to the engine to deck drive blet. 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. Lift the rear corner of the deck and disconnect the rear deck mounting latch. Repeat for
the other side.
D. Position the front caster sheels so they are away from the deck (such as the tractor
would bve traveling in reverse).
E. Attached a hoist to the deck lift bolt. lift the nose of the deck until the deck is standing
vertical and the deck latch engages.
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.
LOWERING THE DECK:
A. While lifting the nose of the deck disengage the deck latch from the locking pin. Push
the bottom of the deck towards the rear of the tractor while holding the deck latch so
that it clears the locking pin. Lower the deck until it rests on the ground.
B. Lift the rear corner of the deck and reconnect the rear deck mounting latch. Repeat for
the otherside.
C. Roll the engine to deck drive belt back onto the center spindle. Insure that the engine
to deck drive belt is installed onto all of the pulleys and idlers in the drive train.
D. Lower the foot deck down into the operation position.
Page 32
CARE AND MAINTENANCE
Cut Height Adjustment Lever
Locking Pin
Deck Latch
Foot Deck
Center Deck Spindle
Deck Lift Bolt
Front Caster Wheels positioned out
of the way
Cut Height Adjustment Pin
Rear Deck Mounting Latch
Rear Corner
MOWER SHOWN IN OPERATION POSITION
Engine to Deck Drive Belt
Hoist
Deck Latch in locked position
Foot Deck in up position
MOWER SHOWN IN SERVICING POSITION
Page 33
STANDARD SERVICE PARTS LIST
MODEL ZTR 7025:
BLADES: 52" Hi-Lift: P/N 60532
60" Hi-Lift: P/N 60295
60" Lo-Lift: P/N 60293
BELTS: Engine To Mower Deck: P/N 60497
Serpentine Belt: P/N60492(52") P/N 60494 (60")
Engine To Hydro: P/N 61593
Hydrostatic Transmission Filter: P/N 7252
KOHLER AIR AND OIL FILTER PART NUMBERS:
Refer to engine manufacturers manual for recommendations regarding frequency of service
required for engine oil changes and air filter maintenance.
Protect your engine investment, use only original equipment filters.
Model ZTR 7025: 25HP Pre-Cleaner Foam Element 45083-01-S
Cartridge Air Cleaner 45083-02-S
Engine Oil Filter 12050-01-S
IMPORTANT:
Some applications, extreme dirt conditions, or the use of a grass catcher may
require that the engine used on the Model ZTR 7025 be fitted with an OPTIONAL
Kohler fresh air filter system.
Consult your dealer or a Kohler engine service center for additional information.
Page 34
TROUBLESHOOTING
1. ENGINE WON'T TURN OVER
Mower blades engaged
Drive not in neutral
Blown fuse
Dead battery
Solenoid
Ignition switch
Starter
2. ENGINE WILL TURN OVER BUT WON'T START
No gas
Over or under choked
Spark plug not firing
Carburetor maladjustment
Ignition Switch
3. HARD TO START ENGINE
Fuel line clogged
Faulty fuel pump
Spark plug wire loose or grounded
Spark plug(s) faulty or improperly gapped
Electronic ignition defective
Dirty or maladjusted carburetor
-------------------------------------------------------------------------------------------------------------------------------replace fuse
---------------------------------------------------------------------------------------------------------------------charge or replace
-------------------------------------------------------------------------------------------------------------------------------consult dealer
-------------------------------------------------------------------------------------------------------------------------consult dealer
----------------------------------------------------------------------------------------------------------------------------------consult dealer
-------------------------------------------------------------------------------------------------refuel and/or clean or replace fuel filters
---------------------------------------------------------------readjust carburetor* or consult dealer for carburetor service
--------------------------------------------------------------------------------------------------------disengage blades
----------------------------------------------------------------move steering control levers to neutral "OUT " position
----------------------------------------------------------------------------------------------------------------adjust choke
-------------------------------------------------------------------------------------------------------------check spark plug
--------------------------------------------------------------------------condition and reset gap*/consult dealer
--------------------------------------------------------------------------------------------clean fuel line and check fuel filter
---------------------------------------------------------------------------------------------------------------------consult dealer
-----------------------------------------------------------------------------------check spark plug wires
----------------------------------------------------------------------------------check spark plug
-------------------------------------------------------------------------------------------condition and reset gap*
consult dealer
readjust carburetor* or consult dealer for carburetor service
4. ENGINE STARTS BUT CUTS OUT
Water in gasoline
Clogged fuel line
Vent in fuel cap plugged
Faulty fuel pump
Maladjusted carburetor
Engine dies when control levers are moved "IN"
5. ENGINE KNOCKS
Low oil level
Ignition timing off
Fuel octane too low
Over heated engine
-----------------------------------------drain old gasoline-replace with new gasoline and /or clean carburetor bowl
-------------------------------------------------------------------------------clean carburetor bowl and or check fuel filter
------------------------------------------------------------------------------------------------------------clean fuel line
-------------------------------------------------------------------------------------------------------------------------check vent
-------------------------------------------------------------------------------------------------------------consult dealer
----------------------------------------------------------------------------------------------------------------------check and add oil
---------------------------------------------------------------------------------------------------------------------consult dealer
---------------------------------------------------------------------------drain and replace with higher octane gasoline
-------------------------------------------------------------------------------------------shut off engine and allow to cool
------------------------------------------------------parking brake set -- release brake
*See engine manual for engine adjustments
Page 35
TROUBLESHOOTING
6. ENGINE SOMETIMES SKIPS AT HIGHER SPEED
Incorrect ignition timing
Carburetor maladjusted
Faulty spark plugs
7. ENGINE OVERHEATED
Air intake screen or fins clogged
Fuel mixture too lean
Oil level too low or too high
Improper ignition timing
Running engine too slow
8. ENGINE IDLES POORLY
Carburetor maladjustment
Improper spark plug gap
9. ENGINE BACKFIRES
Carburetor maladjustment
----------------------------------------------------------------------------------------------------------------Consult dealer
--------------------------------------------------------------------------------------------------------Readjust carburetor
-------------------------------------------------------------------------------Check spark plug or condition and reset gap*
-----------------------------------------------------------------------------------Clean Intake screen and fins
----------------------------------------------------------------------------------------------------------Readjust carburetor*
-----------------------------------------------------------------------------------------------------------Adjust oil level
-----------------------------------------------------------------------------------------------------------Consult dealer
-----------------------------------------------------------------------------------------------------------Run engine faster
----------------------------------------------------------------------------------------------------Readjust carburetor
--------------------------------------------------------------------------------------------------Check and re-gap plug*
---------------------------------------------------------------------------------------------------Readjust carburetor*
(NOTE: Always mow at full throttle setting.)
10. ENGINE RUNS BUT MOWER WON'T MOVE FORWARD
Drive belt broken or slipping
Shift linkage cable disconnected
Transmission shift arm disconnected
Transmission oil low
Transmission locks in free wheel position
Hydrostat oil filter plugged
Bad transmission
Gear mating transmission/gearbox disconnected
11. MOWER LOSES POWER OR TRANSMISSION
OVERHEATS
Hydrostat transmission oil too low or too high
Transmission damage
Transmission blowing oil out cap
12. ENGINE STALLS WHEN BLADES ARE ENGAGED
Operator not on seat
Faulty interlock system
Bad blade spindle bearing
Deck drive belt not properly routed
Blades blocked by foreign material
-----------------------------------------------------------------------------------------------------------------------Consult dealer
-----------------------------------------------------------------------------------------------------Replace drive belt
---------------------------------------------------------------------------------------------------------Reconnect
---------------------------------------------------------------------------------------------------Reconnect
----------------------------------------------------------------------------------------------------------------------------Add oil
---------------------------------------------------------------------Put in lock position (see pg. 5)
--------------------------------------------------------------------------------------------------------------Replace filter
-------------------------------------------------------------------------------Consult dealer
-----------------------------------------------------------------Add Oil or drain oil as needed
-----------------------------------------------------------------------------------------------------------------Consult dealer
-----------------------------------------------------------------------------Overfilled or water contaminated
------------------------------------------------------------------------------------------------------------------------Sit on seat
----------------------------------------------------------------------------------------------------------------Consult dealer
-----------------------------------------------------------------------------------------------------------Consult dealer
---------------------------------------------------------------------------------------------------------Reroute
---------------------------------------------------------------------------------------------Clean under deck
Page 36
*See engine manuals for engine adjustments
NOTES
Page 37
NOTES
Page 38
OWNER
INFORMATION
DATE PURCHASED
MOWER MODEL NUMBER
MOWER SERIAL NUMBER
PURCHASED FROM
Name
Address
DIXON INDUSTRIES, INC.
A BLOUNT International Inc. Co.
PO BOX 1569
COFFEYVILLE KS 67337 0945
316 251 2000
FAX 316 251 4117
DATE OIL CHANGED: DATE ENGINE TUNED:
Page 39
W ARNING:
Dixon® and ZTR® are registered trademarks of Dixon Industries, Inc.
DIXON INDUSTRIES, INC.
a BLOUNT International Inc. Co.
PO Box 1569
Coffeyville, Ks 67337 0945
316-251-2000
Page 40
The engine exhaust from this product contains chemicals known to the
State of California to cause cancer, birth defects or other reproductive harm.
7000 Series
7025
Part No. 13091-0500
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