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Operator's Manual
8000 SERIES
ZTR® MOWERS
Page 2
IMPORTANT - READ CAREFULLY
The Dixon®ZTR®Mower is both easy and fun to operate. H oweve r , any po wer mower
must be operated properly to be safe. It is not a toy or a r ecr eational vehicle. Befor e you
start to use the mower , read the operator's manual car efully and become completely
familiar with the controls.
The information in this operator's manual applies to all Dixon® ZTR®8000 Series
Commercial Mow ers. 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
2
Page 3
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
8000 Series
Part No. 13092-0700
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Page 4
SAFETY
RIDING LAWNMOWERS, IF IMPROPERLY OPER-
ATED, CAN CAUSE SERIOUS INJURY OR DEATH
The most common causes of injury to the operator or bystander...
BLADE CONTACT
RUN-OVER
TIP-OVER
BACK-OVER
...read and understand this manual to prevent injuries.
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Page 5
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.
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Page 6
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 mow er into a trailer or truck. Do not ride the mo wer
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 manufactur er's recommendation for wheel weights or counterweights.
• Maintain or replace safety and instruction labels, as necessary.
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Page 7
SLOPE OPERATION:
Slopes are a major factor related to loss-of-control and tip-over accidents,
which can result in severe injury or death.
SAFETY
All slopes require extra caution.
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.
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Page 8
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.
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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 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 immediatley.
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.
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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 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.
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.
AND WORKMANSHIP AND PROVIDES FOR REPLACEMENT OR REPAIR OF PARTS INCLUDING
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
Commercial Application: Dixon mowers used for commercial application are warranted for one (1) year
DIXON ZTR MOWERS ARE WARRANTED AGAINST DEFECTS IN MATERIALS
LABOR COSTS. THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS
AND LIMITATIONS:
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.
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
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SPECIFICATIONS
Specifications go here
8000 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 60"
or 72" cut width. Cut height approximately 1.5" to 6" via 11 position lift handle.
BLADE DRIVE: Electric clutch
DRIVE SYSTEM: Each rear wheel is independently driven by a HydroGear BDA pump and White
CE wheel 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 13-6.5x6
Rear 23-10.5x12
RECOMMENDED Front 12 lbs.
TIRE PRESSURE: Rear 12 lbs.
CAPACITIES: Fuel - 11.5 gallons (approx)
Hydrostat oil tank - 4 quart with in-line 40 micron filter
Hydrostat oil recommendation, refer to page 36
Engine - 2 qts. SAE 10W30 (with filter)
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
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SEAT ADJUSTMENT INSTRUCTIONS
8000 Series Models
FORE & AFT ADJUSTMENT
1. Grasp seat slide adjuster and move it into adjustment position.
2. Slide seat forward or backward.
3. Release seat slide adjuster .
SEA T BACK ADJUSTMENT
1. Rotate knob clockwise to recline.
2. Rotate knob counter-clockwise to raise.
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CONTROLS
SHOW HOW TO REMOVE BOOT & RAISE
AND LOWER & ROTATE CONTROL
HANDLES
ADD INFO ON HEADLIGHT POSITION ON
START SWITCH
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CONTROLS
PARKING 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.
.
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 mow er .
HYDRO-GEAR DRIVE SYSTEM:
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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.
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CONTROLS
SHOW HOW TO REMOVE BOOT & RAISE
AND LOWER AND ROTTTE CONTROL
HANDLES.
ADD
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Page 16
BLADE DRIVE:
Located on control panel, on operator's right.
To engage blades: Pull up on the switch.
To disengage blades: Push down.
CONTROLS
MOWER DECK CUT HEIGHT LIFT LEVER:
Located to the right and front of operator.
Controls the cutting height.
Eleven positions of adjustment.
NOTE: Always use high position for transport.
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Page 17
OPERA TION 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
functions.
During initial operation, "learning to drive", set throttle at slow speed.
Sound judgement by the owner will prevent accidents.
allow anyone to operate the mower without complete knowledge of all controls and their
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.
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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 off position)
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OPERA TION INSTRUCTIONS
TESTING OF SAFETY INTERLOCK SYSTEMS:
Do not operate mower if safety switches are not operating properly.
Y our 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 brake is "SET" and the steering control levers
are moved to the "IN" position.
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 .
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OPERATION INSTRUCTIONS
ST ARTING INSTRUCTIONS: Cold Engine
1. Push throttle control lever to 1/2 setting.
2. Push choke control lever forward.
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 back to the 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 insure adequate
lubrication, cooling and cut quality of the mower deck.
NOTE: Model ZTR 8025 will
require a slightly longer
warm up period using
partial choke settings.
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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 wide open or maximum setting for
actual operation of the mower deck.
NOTE: Model ZTR 8000 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.
while mower blade is engaged.
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
Always turn engine off when leaving mower.
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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 beginning on
page 35.
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 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.
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"
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
every 50 hours
(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
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Check spark plugs . . . . . . . . . . . . . . . . . . . . . . . . annually or every
500 hours
Page 23
CARE AND MAINTENANCE
ENGINE:
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
sulfuric acid solution. Avoid spilling on skin,
BATTERY:
eyes and clothing.
Check the fluid in the battery at frequent intervals.
Keep fluid level abov e 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.
ALW AYS 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.
Battery electrolyte is a poisonous and corrosive
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 -12 lbs.
Rear tires - 12 lbs.
Lug nuts or lug bolts should be checked regularly for tightness.
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CARE AND MAINTENANCE
Stop engine, remove ignition key and spark plugs for
CAUTION
MOWER BLADES:
To sharpen blades, proceed as follows.
?? A. Remove bolt, lock washer, and cup washer mounting blade on
shaft. Remove blade.
ener. Wear gloves and eye protection when sharpening.
Grind blade at original 25
safety. Wear heavy, thick gloves when holding onto
cutter blade, avoid the sharp edge of the blade.
Check sharpness of mower blades after every 10 hours of operation.
B. Blades should be discarded when worn excessively .
C. Sharpen blade with a hand file, electric grinder or blade sharp-
degree bevel.
D. 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.
E. Install blade, cup washer, lock washer and bolt. Make sure to
tighten bolt to 60 ft. lbs.
New
Blade
25
degrees
When notch starts,
discard blade
DANGER-
OUS!
DO NOT USE
BLADE IN
THIS
CONDITION!
BELTS:
Check belts 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.
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CARE AND MAINTENANCE
LUBRICATION:
A. Engine: Follow engine manufacturer's recommendation.
B. Deck spindles: Lubricate 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 HYDRO-
STATIC 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
new instructions & graph-
Fuel
Cap
Please dispose of used oil at proper collection centers - protect your environment
ics. no dipstick
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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.
Castle
Nut
.010 between Brake Disk and Brake Puck
Actuating
Lever
Brake Linkage Spring
Stop
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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 PRO-
CEDURE:
(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" to 1/2" when measured at mid-point between hydro and idler pul-
ley.
Hydrostat Drive
Pulley
Hydrostat Drive
Belt
27
3/8" Pin and Rue-Ring
new instructions & graphics.
Motor Pulley
Idler
Pulley
3/8" bolt, lockwasher & heavy
washer
Page 28
CARE AND MAINTENANCE
STEERING CONTROL ADJUSTMENTS
new instructions & graphics.
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.
28
front is the stop for REV.
NOTE: The one at the rear is the stop for FWD and the one in the
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 loosened
earlier.
5. Recheck to make sure neutral adjust has not been effected, see
procedure A.
Steering Control
Lever
new in-
structions &
graphics. Access
Hole
Upper linkage As-
sembly
RH Locknut
Forward
Stop
Setscrew
Rod End Ball
LH Locknut
Joint
Turn this
rod to
Adjust
Neutral
Inward Stop
Setscrew
Reverse Stop
Setscrew
Setscrew used to
adjust Forward Tracking
29
Loosen Bolt on Linkage
Page 30
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).
new instructions & graphics.
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
30
Page 31
CARE AND MAINTENANCE
PROCEDURE FOR RAISING AND LOWERING THE
DECK
FOR SERVICING
new instructions & graphics.
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.
31
Page 32
CARE AND MAINTENANCE
Cut Height Adjustment
Lever
Locking
Pin
Deck
Latch
Foot
Center Deck Spindle
Deck Lift
Bolt
Deck
new instructions & graphics.
Front Caster Wheels positioned
out of the way
MOWER SHOWN IN OPERA TION POSITION
Cut Height Adjustment
Pin
Rear Deck Mounting
Latch
Rear
Corner
Engine to Deck Drive Belt
Hoist
Deck Latch in locked
position
Foot Deck in up position
32
MOWER SHOWN IN SER VICING POSITION
Page 33
STANDARD SERVICE PARTS LIST
MODEL ZTR 8025:
BLADES: 60": P/N
72": P/N
BELTS: Engine To Mower Deck: P/N
Serpentine Belt: P/N
Engine To Hydro: P/N
Hydrostatic Transmission Filter: P/N
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 8025: 25HP Pre-Cleaner Foam Element
Cartridge Air Cleaner
Engine Oil Filter
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.
Listed below are the Kohler kit numbers required to adapt these
components to the engine. Consult your dealer or a Kohler engine
service center for additional information.
33
Model ZTR 8025: 25HP Check with xxxxxxx Dealer for
availability
Page 34
TROUBLESHOOTING
1. ENGINE WON'T TURN OVER
------------------------------------------------------------------------------------------------
Mower blades engaged
Drive not in neutral
----------------------------------------------------------------move steering control levers
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
--------------------------------------------------------------------------condition and reset
Dirty or maladjusted carburetor
---------------------------------------------------------------readjust carburetor* or con-
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"
-----------------------------------------------------------------------------------check spark
5. ENGINE KNOCKS
----------------------------------------------------------------------------------check spark
Low oil level
Ignition timing off
Fuel octane too low
Over heated engine
-------------------------------------------------------------------------------------------
readjust carburetor* or consult dealer for carburetor service
-------------------------------replace fuse
---------------------charge or replace
-------------------------------consult dealer
-------------------------consult dealer
----------------------------------consult dealer
-refuel and/or clean or replace fuel filters
sult dealer for carburetor service
clean fuel line and check fuel filter
---------------------consult dealer
--------disengage blades
to neutral "OUT " position
----------------adjust choke
-------------check spark plug
gap*/consult dealer
condition and reset gap*
consult dealer
plug wires
plug
34
-----------------------------------------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
------------------------------------------------------parking brake set -- release brake
Page 35
TROUBLESHOOTING
------------------------------------------------------------------------------------------------
6. ENGINE SOMETIMES SKIPS AT HIGHER SPEED
------------------------------------------------------------------------------------------------
Incorrect ignition timing Carburetor
maladjusted
-------------------------------------------------------------------------------Check spark
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
-----------------------------------------------------------------------------------Clean
----------------Consult dealer
--------Readjust carburetor
plug or condition and reset gap*
Intake screen and fins
----------Readjust carburetor*
-----------Adjust oil level
-----------Consult dealer
-----------Run engine faster
(NOTE: Always mow at full throttle setting.)
9. ENGINE BACKFIRES
Carburetor maladjustment
------------------------------------------------------------------------------------------------
----Readjust carburetor
------------------------------------------------------------------------------------------------
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
----------------------------Add oil
---------------------------------------------------------------------Put in lock position (see
12. ENGINE STALLS WHEN BLADES ARE
------------------------------------------------------------------------------------------------
ENGAGED
Operator not on seat
------------------------------------------------------------------------------------------------
Faulty interlock system
Bad blade spindle bearing
-------------------------------------------------------------------------------Consult dealer
Deck drive belt not properly routed
Blades blocked by foreign material
-----------------------Consult dealer
--Check and re-gap plug*
---Readjust carburetor*
-----Replace drive belt
---------Reconnect
---Reconnect
--------------Replace filter
pg. 5)
35
-----------------------------------------------------------------Add Oil or drain oil as
Page 36
NOTES
36
Page 37
NOTES
37
Page 38
OWNER
INFORMATION
DATE PURCHASED
MOWER MODEL NUMBER
MOWER SERIAL NUMBER
DIXON INDUSTRIES, INC.
A BLOUNT International Inc. Co.
PO BOX 1569
COFFEYVILLE KS 67337 0945
316 251 2000
FAX 316 251 4117
PURCHASED FROM
DATE OIL CHANGED: DATE ENGINE TUNED:
Name
Ad-
dress
38
Page 39
WARNING
The engine exhaust from this product contains chemicals known to
the
State of California to cause cancer, birth defects or other repro-
ductive harm.
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
8000 Series
8025
Part No. 13092-0700
39
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