Dixon ZTR 8000G Series manual

ZTR ® 2003 OPERATORS MANUAL 8000G SERIES[...]

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 [...]

3 INDEX Page Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 2 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-18 Operation[...]

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 serio[...]

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 rock[...]

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 crossing roadways. Use extra care when loa[...]

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 ro[...]

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 adu[...]

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[...]

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[...]

12 DIXON INDUSTRIES, INC. a BLOUNT company Airport Industrial Park P.O. Box 1569 Coffeyville, Ks 67337- 0945 620-251-2000 Fax 620-251-4117 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 mo[...]

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 weld[...]

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[...]

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 b[...]

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 comple[...]

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 pa[...]

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[...]

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 neutr[...]

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 e[...]

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 eng[...]

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 con[...]

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 m[...]

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 clevis end of the seat damper from the seat hold down bracket and replace the pin and rotating pin clip t[...]

26 OPERATION INSTRUCTIONS TO FREE WHEEL MACHINE (UNLOCK TRANSMISSION): Always turn off engine before engaging or disengaging the hydro release (free wheel) valves. Never attempt to move the valves with the engine running. The hydro release valves are located beneath the seat on the top of the hydro pumps on each side of the machine. To unlock the t[...]

27 CARE AND MAINTENANCE CAUTION CAUTION CAUTION CAUTION CAUTION Bef Bef Bef Bef Bef ore perf ore perf ore perf ore perf ore perf or or or or or ming an ming an ming an ming an ming an y maintenance y maintenance y maintenance y maintenance y maintenance , tur , tur , tur , tur , tur n off engine n off engine n off engine n off engine n off engine ,[...]

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. BA[...]

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 protectio[...]

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 approxi[...]

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 i[...]

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 [...]

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. HYD[...]

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 f[...]

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[...]

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 e[...]

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[...]

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 Transmiss[...]

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- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -[...]

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- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - [...]

42 NOTES[...]

43 OWNER INFORMATION Date Purchased _ ________________________________ Mower Model Number ____________________________ Mower Serial Number ____________________________ Purchased From ___ _____________________________ Name ________________________________ Address ________________________________ DATE OIL CHANGED: DATE ENGINE TUNED: _________________[...]

ZTR®Mowers ZTR®Mowers ZTR®Mowers ZTR®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. 13637-xxxx W W W W W ARNING: ARNING: ARNING: ARNING: ARNING: The engine ex[...]