Dixon 8000 series, ZTR 8000 SERIES Operator's Manual

ZTR®

OPERATOR’S MANUAL

8000 SERIES

(Gas Version)

2002

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 contained in this manual applies to all
Dixon® ZTR® 8000 Series (Gas Version) Commercial
Mowers. Your Dixon dealer will gladly answer any questions.

See your dealer for warranty service, parts and repairs.

3

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. 13092-0901

4

RIDING LAWN MOWERS,

IF IMPROPERLY OPERATED,

CAN CAUSE SERIOUS INJURY OR DEATH.

The most common causes of injury to the operator or bystander...

...read and understand this manual to prevent injuries.

BLADE CONTACT

TIP OVER

RUN OVER

BACK OVER

SAFETY

5

Safety Alert Symbol

When you see this symbol,

BE ALERT to the potential for injury.

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.

Follow recommended safety precautions

and safe operating practices.

SAFETY

6

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.

SAFETY

7

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.

SAFETY

8

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.

SAFETY

9

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.

10

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.

SAFETY

11

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.

SAFETY

12

DIXON INDUSTRIES, INC.
a BLOUNT company
Airport Industrial Park
P.O. Box 1569
Coffeyville, Ks 67337- 0945
620-251-2000
Fax [phone]

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. Routine maintenance or adjustments.
c. Belts/cutting blades/hydrostatic filters.
d. Engines - All engines used on Dixon ZTR mowers are warranted by the individual engine

manufacturer.
e. Any costs or expense of providing substitute equipment while repair work is being

performed on a warranted mower.

7. There is no other express warranty. Implied warranties, including those of merchantability and fitness
for a particular purpose, are limited to the same duration of the express warranty, and to the extent
permitted by law any and all implied warranties are excluded. Liabilities for consequential damages
under any and all warranties are excluded.

Blue/Customer Yellow/Dealer White/Dixon Ind.

WARRANTY VALIDATION: At the time of sale, selling dealer must review each portion of this
warranty document, complete the information section below, secure customer’s signature &
send copy to Dixon Industries, Inc.

DATE OF PURCHASE____________________MODEL___________________S/N_______________
_____________________________________ ______________________________________
Owner’s Name Dealership
_____________________________________ ______________________________________
Address Address
______________________________________ _______________________________________

_____________________________ ______________________________

Owner’s Signature Dealer’s Signature

13

SPECIFICATIONS

8000 Series (Gas Version)

CHASSIS:

11 GA - rectangular tube, 7 GA reinforcement

SEAT:

Designed for operator comfort with padded back & arm
rests. Seat is adjustable fore & aft. Seat back tilts. Mounted
on operator suspension system with damper.

MOWER DECK:

2 decks are available. Both decks are made of 10 GA
fabricated welded construction with 1/4 " reinforcement
plate. 3 blades combine for either a 60" or 72" cut width. Deep
deck with discharge tunnel. Cut height approximately 1.5" to
6" via 10 position lift handle.

BLADE DRIVE:

"V" Belt with Electric clutch

DRIVE SYSTEM:

Each rear wheel is independently driven by a HydroGear BDP­10A pump and White CE wheel motor.

ENGINE:

25HP Kohler Command, 4-Cycle, V-Configuration, Overhead
Valve, Air-Cooled, Gasoline, Horizontal Shaft, Aluminum Head
and Crankcase with Cast Iron Liners, Full Pressure
Lubrication/Full Flow Filter, Pulse-type Fuel Pump, Fixed Jet
Carburetor, Electronic Ignition, In-Line Fuel Filter, Dual Element
Air Cleaner.

STARTING SYSTEM:

Electric by key switch operation with safety interlocks on
parking brake, blade drive clutch and control levers.

TIRES:

Front 13-6.5x6
Rear 23-10.5x12

RECOMMENDED

Front 16-20 lbs.

TIRE PRESSURE:

Rear 8-14 lbs.

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 73.5"(60" Deck), 85.5"(72" Deck)
Height 54"
Length 87"
Weight 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.

14

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.

15

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) Grasp lever with right hand.

2) Depress thumb lever to release. Move to desired position.

3) 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.

CONTROLS

16

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.

CONTROLS

17

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.

18

CONTROLS

19

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. Check engine oil.

4. Check fuel cap to be sure it is in place.

5. Be sure parking brake is on.

6. Mower blade drive is off.

7. Know how to stop engine. (Turn key to off
position).

20

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 engine will not start if the mower blades are
engaged.

2. The engine will not start unless the steering control
levers are neutral “OUT” position.

3. The engine will stop if the mower blade clutch is
engaged and the operator leaves the driver’s seat.

4. The engine will stop if the park brake is ON and the
steering control levers are moved to the “IN” position.

21

INTERLOCK SWITCH TEST

Note: Operator must be seated in normal operating position to

perform these tests.

1. With engine off, turn mower blade on and attempt to
start engine.
ENGINE SHOULD NOT START.

2. With engine off, move control levers in and attempt to
start engine.
ENGINE SHOULD NOT START

3. 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.

OPERATION INSTRUCTIONS

22

OPERATION INSTRUCTIONS

STARTING INSTRUCTIONS:

1. Operator must be seated in normal operating position.

2. Set parking brake.

3. Move control levers to outboard position.

4. Assure blade clutch is off.

5. Push throttle control lever to 1/2 setting.

6. 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. Insert Ignition key and turn to start position. When engine
starts, release ignition key. Key will return to “run” position.

8. 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.

CAUTION

STOPPING INSTRUCTIONS:

1. Turn mower blades off.

2. Move control levers to outboard position.

3. Set parking brake.

4. Move throttle control to slow. Allow engine to run a
short time to cool down then turn ignition key to “OFF”
and remove key.

Do not operate the engine in an enclosed area
due to the harmful exhaust gas produced.

23

OPERATION INSTRUCTIONS

MOWING INSTRUCTIONS:

CAUTION Be sure that deflector is properly

installed on the discharge chute.

1. Start engine and set throttle at full speed.

2. Set desired cut height.

3. Release park brake.

CAUTION Check the area to assure there is no

one near.

4. Engage mower blades.

5. Move control levers in and operate per the
controlinstructions on Page 14.

24

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 1 - 2”

Bluegrass 2 - 3”
Buffalograss 1

1/2

-3”
Ryegrass 2 - 3”
Tall Fescue 3 - 3

1/2

”

Zoysiagrass 1 - 3”

25

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.

26

OPERATION INSTRUCTIONS

TO FREE WHEEL MACHINE (TOWING):

The transmission 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.

27

CARE AND MAINTENANCE

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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

28

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:

•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 - 16-20 lbs.
Rear tires - 8-14 lbs.

Lug nuts or lug bolts should be checked regularly for tightness.

CAUTION

Battery contains sulfuric acid electrolyte which is
poisonous and corrosive.

29

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.

CARE AND MAINTENANCE

BELTS:

Check belts every 50 hours. Replace any belts found to be in poor
condition.

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.

DANGEROUS!

DO NOT USE
BLADE IN THIS
CONDITION!

When notch starts,
discard blade

New Blade

30

CARE AND MAINTENANCE

LUBRICATION:

1. Engine: Follow engine manufacturer’s recommendation.

2. Deck spindles: Lubricate with 3 “shots” only, every 100 hours.

3. Mower chassis: Lubricate with 3 “shots” only, every 50 hours (see
zerk locations below).

31

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

32

CARE AND MAINTENANCE

1. Loosen the locking screw on the top

knob of the brake engaging handle.

2. 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. Set the brake for the holding power

required for the intended use and the
desired force required to activate it.

4. Retighten the knob locking screw.

PARKING BRAKE ADJUSTMENT

33

1. Loosen the 1/2” retaining nut underneath the
headlight and slide the headlight forward out of
the fuel tank.

2. 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. Replace headlight in fuel tank.

4. Swivel the headlight horizontally to illuminate
the desired area and tighten the headlight
retaining nut.

CARE AND MAINTENANCE

HEADLIGHT ADJUSTMENT

34

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. Raise seat. (See instructions on Page 25).

2. 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. Install belt per diagram.

3. Re-attach belt cover.

4. Return the seat to the operating position.

35

STEERING CONTROL ADJUSTMENTS:

To adjust neutral:

1. Lift seat (see instructions on Page 25).

2. Block up the unit so that the drive wheels are off
the ground.

3. Loosen ball joint jam nuts on control rod.
Note: The front jam nuts are left hand threads.

4. With steering control arms in the “out” neutral
position, start the engine and run at fast idle.

5. Adjust the neutral position by turning the control
rod until the wheels do not rotate.

6. Re-tighten the jam nuts on the control rod and
check to see that the drive wheels are not turning.

7. Repeat steps 3-6 for the other side.

8. Shut off engine before removing the blocks.

9. 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. Move control handle full forward.

3. Move front spring stop collar rearward until it
compresses spring approximately 1/16” and
tighten collar set screw.

4. Move control handle full rearward.

5. 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.

CARE AND MAINTENANCE

36

STEERING CONTROL ADJUSTMENTS (continued):

CARE AND MAINTENANCE

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. Move the levers inboard to the operating
position.

3. Loosen the set screw of the clamp collars which
lock the upper arms to the lower arms.

4. 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. Rotate arms until they have the desired
orientation front to back.

6. Tighten the clamp collar set screws.

37

To adjust “In” position of the steering controls

1. Move the levers inboard to the operating position.

2. 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. Stop the machine and shut off the engine.

3. 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.

CARE AND MAINTENANCE

STEERING CONTROL ADJUSTMENTS (continued):

38

CARE AND MAINTENANCE

LEVELING THE DECK:

1. Set the tire pressure on all four 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. Loosen the jam nuts on the front and rear deck
hangers.

6. Rotate the 2 outer spindles so the blades point
outboard.

7. Adjust front hangers to level deck side to side.

8. 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.

39

STANDARD SERVICE PARTS LIST

MODEL ZTR 8025:

Blades (60”) standard: P/N 12421

low lift: P/N 12451
Gator: P/N 12508

Blades (72”) standard: P/N 12339

low lift: P/N 12452
Gator: P/N 12509

Engine to Mower Deck Belt: P/N 12172
Serpentine Belt (60”): P/N 9758
Serpentine Belt (72”): P/N 12033
Engine to Hydro Belt: P/N 12012

Hydrostatic Transmission Filter: P/N 7252

KOHLER AIR AND OIL FILTER PART NUMBERS:

Refer to engine manufacturer’s 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 8025 (25 HP):

Air Filter & Pre-Cleaner Kit 78003
Engine Oil Filter 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.

40

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. 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

3. 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. 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

5. 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

TROUBLESHOOTING

41

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 level

l

Running engine too slow- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -run engine faster

(NOTE: Always mow at full throttle setting)

7. 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*

8. 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. ENGINE BACKFIRES

Carburetor maladjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -readjust carburetor

11. ENGINE IDLES POORLY

Carburetor maladjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -readjust carburetor
Improper spark plug gap- - - - - - - - - - - - - - - - - - - - - - - - - - - - - check and re-gap plug*

*See engine manual for engine adjustment

42

NOTES

43

OWNER
INFORMATION

Date Purchased _________________________________
Mower Model Number ____________________________
Mower Serial Number ____________________________
Purchased From ________________________________

Name

________________________________

Address

________________________________

DATE OIL CHANGED: DATE ENGINE TUNED:

___________________ __________________

_

___________________ ___________________
___________________ ___________________
___________________ ___________________
___________________ ___________________
___________________ ___________________
___________________ ___________________
___________________ ___________________
___________________ ___________________
___________________ ___________________
___________________ ___________________

DIXON INDUSTRIES, INC.
a BLOUNT International Inc. Co.
P.O. Box 1569
Coffeyville, Ks 67337-0945
620-251-2000

FAX [phone]

ZTR®MowersZTR®Mowers

ZTR®MowersZTR®Mowers

ZTR®Mowers

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. 13092-0901

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ARNING:ARNING:

ARNING:ARNING:

ARNING:

The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects or other
reproductive harm.