Dixon Ztr 8025 Users Manual OM, 8000 SERIES 1, 8025, 2001, ZERO TURN

8000 Series DIXO2001_USen_8025_

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8000 SERIES

ZTR® MOWERS

Operator's Manual

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®8000 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

INDEX

8000 Series

Part No. 13092-0700

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

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 TIP-OVER

RUN-OVER BACK-OVER

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

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.

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.

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!

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

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 watch-

ful 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.

CHILDREN:

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 equip-

ment parts, when necessary.

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. 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 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.

(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

Specifications go here

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

SPECIFICATIONS

8000 Series

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.

SEAT BACK ADJUSTMENT

1. Rotate knob clockwise to recline.

2. Rotate knob counter-clockwise to raise.

CONTROLS

SHOW HOW TO REMOVE BOOT & RAISE

AND LOWER & ROTATE CONTROL

HANDLES

ADD INFO ON HEADLIGHT POSITION ON

START SWITCH

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.

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).

Each lever controls one side of the mower.

NOTE: The pressure required to operate the mower is very light.

CAUTION Engage parking brake before starting engine

CONTROLS

SHOW HOW TO REMOVE BOOT & RAISE

AND LOWER AND ROTTTE CONTROL

HANDLES.

ADD

BLADE DRIVE:

Located on control panel, on operator's right.

To engage blades: Pull up on the switch.

To disengage blades: Push down.

MOWER DECK CUT HEIGHT LIFT LEVER:

Located to the right and front of operator.

Controls the cutting height.

Eleven positions of adjustment.

NOTE: Always use high position for transport.

CONTROLS

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.

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 off position)

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 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.

OPERATION INSTRUCTIONS

STARTING 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 opera-

tion 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.

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.

DO NOT operate the engine in an enclosed area

due to the harmful exhaust gas produced.

NOTE: On initial operation, set throttle at slow speed.

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.

CAUTION

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.

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 under-

side of the deck and discharge area.

3. If the grass is tall, place the mower deck cut height lever in the top or sec-

ond 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.

OPERATION INSTRUCTIONS

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 pro-

fessional 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"

CAUTION

CARE AND MAINTENANCE

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

Check spark plugs . . . . . . . . . . . . . . . . . . . . . . . . annually or every

500 hours

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.

CAUTION

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.

Battery electrolyte is a poisonous and corrosive

sulfuric acid solution. Avoid spilling on skin,

eyes and clothing.

CAUTION

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:

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 heavy, thick gloves when holding onto

cutter blade, avoid the sharp edge of the blade.

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. Remove blade.

B. Blades should be discarded when worn excessively.

C. Sharpen blade with a hand file, electric grinder or blade sharp-

ener. Wear gloves and eye protection when sharpening.

Grind blade at original 25

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

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.

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.

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.

CHECKING & REPLENISHING OIL IN HYDRO-

STATIC TRANSMISSION

Please dispose of used oil at proper collection centers - protect your environment

Oil Reservoir Cap

Dipstick

Fuel

Cap

new instructions & graph-

ics. no dipstick

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

Brake Linkage Spring

Stop

Actuating

Lever

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, wash-

ers, 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

3/8" Pin and Rue-Ring

3/8" bolt, lockwasher & heavy

washer

Idler

Pulley

Motor Pulley

Hydrostat Drive

Belt

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.

new instructions & graphics.

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.

NOTE: The one at the rear is the stop for FWD and the one in the

front is the stop for REV.

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

Inward Stop

Setscrew

Reverse Stop

Setscrew

Setscrew used to

adjust Forward Tracking

Loosen Bolt on Linkage

RH Locknut

Upper linkage As-

sembly

Turn this

rod to

Adjust

Neutral

Rod End Ball

Joint

LH Locknut

Forward

Stop

Setscrew

new in-

structions &

graphics. Access

Hole

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).

2 x 4 board, one each corner, just

inside of anti-scalping wheel

Front Deck

Hanger

(one each

side)

Rear Deck Hanger

(one each side)

new instructions & graphics.

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 SUS-

PENSION). 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.

CARE AND MAINTENANCE

MOWER SHOWN IN OPERATION POSITION

Cut Height Adjustment

Lever

Locking

Deck

Latch

Foot

Deck

Center Deck Spindle

Deck Lift

Bolt

Front Caster Wheels positioned

out of the way

Rear Deck Mounting

Latch Rear

Corner

Cut Height Adjustment

Engine to Deck Drive Belt

Hoist

Deck Latch in locked

position Foot Deck in up position

MOWER SHOWN IN SERVICING POSITION

new instructions & graphics.

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 fre-

quency 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.

Model ZTR 8025: 25HP Check with xxxxxxx Dealer for

availability

TROUBLESHOOTING

------------------------------------------------------------------------------------------------

--------disengage blades

----------------------------------------------------------------move steering control levers

to neutral "OUT " position

------------------------------------------------------------------------------------------------

-------------------------------replace fuse

------------------------------------------------------------------------------------------------

---------------------charge or replace

------------------------------------------------------------------------------------------------

-------------------------------consult dealer

------------------------------------------------------------------------------------------------

-------------------------consult dealer

------------------------------------------------------------------------------------------------

----------------------------------consult dealer

------------------------------------------------------------------------------------------------

-refuel and/or clean or replace fuel filters

------------------------------------------------------------------------------------------------

----------------adjust choke

------------------------------------------------------------------------------------------------

-------------check spark plug

--------------------------------------------------------------------------condition and reset

gap*/consult dealer

---------------------------------------------------------------readjust carburetor* or con-

sult dealer for carburetor service

--------------------------------------------------------------------------------------------

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

-----------------------------------------drain old gasoline-replace with new gasoline and /

or clean carburetor bowl

-------------------------------------------------------------------------------clean carbure-

tor bowl and or check fuel filter

------------------------------------------------------------------------------------------------

------------clean fuel line

------------------------------------------------------------------------------------------------

-------------------------check vent

------------------------------------------------------------------------------------------------

-------------consult dealer

------------------------------------------------------parking brake set -- release brake

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

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

TROUBLESHOOTING

------------------------------------------------------------------------------------------------

----------------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

(NOTE: Always mow at full throttle setting.)

------------------------------------------------------------------------------------------------

----Readjust carburetor

------------------------------------------------------------------------------------------------

--Check and re-gap plug*

------------------------------------------------------------------------------------------------

---Readjust carburetor*

------------------------------------------------------------------------------------------------

-----Replace drive belt

------------------------------------------------------------------------------------------------

---------Reconnect

------------------------------------------------------------------------------------------------

---Reconnect

------------------------------------------------------------------------------------------------

----------------------------Add oil

---------------------------------------------------------------------Put in lock position (see

pg. 5)

------------------------------------------------------------------------------------------------

--------------Replace filter

------------------------------------------------------------------------------------------------

-----------------------Consult dealer

-------------------------------------------------------------------------------Consult dealer

-----------------------------------------------------------------Add Oil or drain oil as

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

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

NOTES

DATE PURCHASED

MOWER MODEL NUMBER

MOWER SERIAL NUMBER

PURCHASED FROM

OWNER

INFORMATION

DATE OIL CHANGED: DATE ENGINE TUNED:

Ad-

dress

Name

DIXON INDUSTRIES, INC.

A BLOUNT International Inc. Co.

PO BOX 1569

COFFEYVILLE KS 67337 0945

316 251 2000

FAX 316 251 4117

DIXON INDUSTRIES, INC.

A BLOUNT International Inc. Co.

PO BOX 1569

COFFEYVILLE KS 67337 0945

316 251 2000

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.

WARNING

8000 Series

8025

Part No. 13092-0700

Dixon Ztr 8025 Users Manual OM, 8000 SERIES 1, 8025, 2001, ZERO TURN

8000 Series DIXO2001_USen_8025_

ZTR 8025 to the manual 7b2e0af7-dbb0-43f4-b9d2-e61d0052704a

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