Operator`s manual | Dixon 2560 Lawn Mower User Manual

Model 2560
ZTR®
Model Year 2004
IMPORTANT - READ CAREFULLY
The Dixon ® ZTR® Mower is both easy and fun
to operate. However, any power mower must
be operated properly to be safe. It is not a toy or
a recreational vehicle. Before you start to use
the mower, read the operator’s manual carefully
and become completely familiar with the controls.
The information contained in this manual applies
to all Dixon® ZTR® Model 2560 Mowers. Your
Dixon dealer will gladly answer any questions.
See your dealer for warranty service, parts and
repairs.
INDEX
Page
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . .15
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19
Operation Instructions. . . . . . . . . . . . . . . . . . . 20-28
Care & Maintenance. . . . . . . . . . . . . . . . . . . . . .29-38
Standard Service Parts List. . . . . . . . . . . . . . . . . . . .39
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . .40-41
Model 2560
Part No. 61935-0603
3
SAFETY
RIDING LAWN MOWERS,
IF IMPROPERLY OPERATED,
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.
4
SAFETY
Safety Alert Symbol
When you see this symbol,
BE ALERT to the potential for injury.
Follow recommended safety precautions
and safe operating practices.
DANGER
(highlighted in red)
indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
WARNING
(highlighted in orange)
indicates a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
CAUTION
(highlighted in yellow)
indicates a potentially
hazardous situation which, if not
avoided, may result in minor or
moderate injury. It may also be used
to alert against unsafe practices.
5
SAFETY
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.
6
SAFETY
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 loading or unloading the mower
into a trailer or truck. Do not ride the mower when
loading and unloading.
•Always wear safety goggles or safety glasses with side
shields when operating mower.
•Data indicates that operators, age 60 years and above,
are involved in a large percentage of riding mowerrelated injuries. These operators should evaluate their
ability to operate the riding mower safely enough to
protect themselves and others from serious injury.
•Follow the manufacturer’s recommendation for wheel
weights and counterweights.
•Maintain or replace safety & instruction labels as needed.
The engine exhaust from this product contains chemicals known to the
WARNING: State of California to cause cancer, birth defects or other reproductive
harm.
7
SAFETY
SLOPE OPERATION:
Slopes are a major factor related to loss-of-control and tip-over
accidents, which can result in severe injury or death.
All slopes require extra caution.
If you cannot back up the slope or if you feel uneasy on it,
do not mow it!
DO
•Mow across the slope with your Dixon ZTR - never up
or down.
•Remove obstacles such as rocks, tree limbs, etc .
•Watch for holes, ruts or bumps. Uneven terrain could
overturn the mower. Tall grass can hide obstacles.
•Use slow speed. Tires may lose traction on slopes even
though the brakes are functioning properly.
•Use extra care with grass catchers or other attachments. These can change the stability of the mower.
•Keep all movement on the slopes slow and gradual.
Do not make sudden changes in speed or direction.
8
SAFETY
DO (CONTINUED)
•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.
9
SAFETY
CHILDREN:
Tragic accidents can occur if the operator is
not alert to the presence of children.
Children are attracted to lawn mowers
and the mowing activity.
NEVER assume children will stay
where they were last seen.
Be alert to avoid accidents.
•Keep children out of the mowing area and under the
watchful care of another responsible adult.
•Be alert and turn mower off if a child enters the area.
•Before and during backing, look BEHIND and DOWN
for small children.
•Never carry children. They may fall off and be seriously injured or interfere with safe mower operation.
•Never allow children to operate the mower.
•Use extra care when approaching blind corners,
shrubs, trees, or other objects that may obscure
vision.
10
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 fuel cap or add fuel with engine running.
Allow engine to cool before refueling.
Do not smoke while refueling.
Never refuel the mower indoors.
Never store the mower or fuel container inside a building
where there is an open flame.
If fuel is spilled on clothing, change clothing immediately.
To prevent fire and explosion caused by static electricity:
Never fill containers inside a vehicle or on a truck or
trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before
filling.
When practical, remove fuel-powered equipment
from the truck or trailer and refuel it on the ground.
If this is not possible, then refuel such equipment on
a trailer with a portable container, rather than from a
fuel dispenser nozzle.
If a fuel dispenser nozzle must be used, keep the
nozzle in contact with the rim of the fuel tank or
container opening at all times until fueling is complete. Do not use a nozzle lock-open device.
11
SAFETY
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 build-up.
Clean up oil or fuel spillage. Allow mower to cool before
storing.
•Stop and inspect the equipment if you strike an object.
Repair, if necessary, before restarting.
•Never make adjustments or repairs with the engine running
unless otherwise specified.
•Grass catcher components are subject to wear, damage and
deterioration, which could expose moving parts or allow
objects to be thrown. Frequently check components and
replace with original equipment parts, as necessary.
•Mower blades are sharp and can cut. Wrap the blade(s) or
wear gloves, and use extra caution when servicing them.
•Batteries contain sulfuric acid. To prevent burns avoid
contact with skin, eyes and clothing. To prevent a fire or
explosion keep sparks and open flames away from battery.
•Before disconnecting the negative (-) ground cable, make
sure all switches are OFF.
12
DIXON LIMITED WARRANTY POLICY
Pro Models 1950 ~ 2300 ~ 2560
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. Home Owner Application: Dixon Model 2560 used only at owner’s primary place of residence
is warranted for a period of two (2) years from date of purchase. Frame, body panels and
fenders are warranted for the life of the mower.
2. Commercial Application: Defined as use other than, or in addition to, mowing at owner’s
primary place of residence. Units used in commercial application are warranted for a period of
one (1) year from date of purchase or 400 hours of use, whichever comes first.
3. Warranty applies only to original retail purchaser of new and unused mowers and accessories.
4. 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.
5. Battery Warranty: limited to 90 days from date of purchase.
6. Accessories Warranty (grass catchers, snow blades, covers, etc.): Limited to 90 days from
date of purchase.
7. 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
VOIDS ALL WARRANTY.
8. 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/blades/hydro 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.
9. 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.
13
SPECIFICATIONS
Model 2560
CHASSIS:
Folded sheet metal and rectangular tube
BODY:
Folded sheet metal
SEAT:
Designed for operator comfort with suspension system and
padded back and arm rests. Seat is adjustable fore and aft.
MOWER DECK: Deck is made of 10 GA fabricated welded construction with 7
GA reinforcement plates. Three blades combine for a 60" cut
width. Cut height approximately 1.5" to 5" via 10 position lift
handle.
BLADE DRIVE:
Electric clutch
DRIVE SYSTEM: Each rear wheel is independently driven by a HydroGear BDP
10A pump and a White CE 14 hydraulic 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 13-5.00x6
Rear 23-9.50x12
RECOMMENDED Front
TIRE PRESSURE: Rear
12 lbs.
12 lbs.
CAPACITIES:
Fuel - 11 gallons (approx)
Hydrostat oil system - 4 qt with in-line 40 micron filter
Hydrostat oil recommendation, refer to page 31
Engine - 2 qts. SAE 10W30 (with filter)
DIMENSIONS:
Width
Height
Length
Weight
69-1/2"
43"
81”
916 lbs.
Additional information provided in service instructions under the individual
component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
14
SEAT ADJUSTMENT INSTRUCTIONS
Model 2560
1.
Grasp seat slide adjuster and move it into
adjustment position.
2.
Slide seat forward or backward.
3.
Release seat slide adjuster.
Seat Slide Adjuster
15
CONTROLS
16
CONTROLS
CONTROL LEVERS
Note:
For access to the seat, move control levers to neutral position and
swing them outward.
TO GO FORWARD:
•From neutral position, gently push both control levers
forward.
•To increase speed, move levers further forward.
TO GO BACKWARD:
•From neutral position, gently pull both control levers
toward you.
TURNING:
•Turning is controlled by moving one control lever
slightly forward or rearward of the other.
•To turn left, move left lever rearward of the right lever.
move right lever rearward of the left lever.
•To turn on mower’s own axis (zero turning radius), stop
and move one lever to reverse position and the other to
forward position.
BRAKING:
•To brake mower, move both levers in direction opposite
of travel.
LEFT TURN OPPOSITE
Note: The pressure required to operate the mower is very light.
17
CONTROLS
CHOKE CONTROL LEVER:
•Located on control panel to operator’s right.
•Used to start a cold engine.
THROTTLE CONTROL LEVER:
•Located on contol panel to operator’s right.
•Controls engine speed, slow to maximum.
•While moving, throttle control should be set to MAXIMUM or wide
open setting to insure adequate cooling of the engine & to maintain
mower deck blade speed.
PARKING BRAKE:
The hand operated parking brake is located on the left of the mower.
It is designed to hold the mower from moving and is not intended for
use in stopping the mower while it is in motion.
To engage brake: pull lever upward.
To disengage brake: push lever downward.
Note:
Note:
Always set parking brake before dismounting. Release
the parking brake before moving mower.
Engage parking brake before starting engine.
HYDRAULIC 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.
18
CONTROLS
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 the
operator.
Controls the cutting height.
Ten positions of adjustment.
Depress trigger and move lever
forward to lower deck.
Depress trigger and pull lever back
to raise deck.
Note:
Always use high position
for transport.
19
OPERATION INSTRUCTIONS
The safe and successful operation of the ZTR
Model 2560 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.
20
OPERATION INSTRUCTIONS
BEFORE OPERATING MOWER:
1.
Read and observe all safety instructions on
your mower and in the manual.
2.
Read engine manufacturer’s operating and
maintenance instructions.
3.
Discuss proper maintenance with your
dealer.
4.
Check engine oil.
5.
Check fuel 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).
21
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 mower blades must be disengaged before the
engine will start.
2. The brake lever must be engaged (upward position)
before engine will start.
3. The engine will stop if the mower blade clutch is
engaged when the operator leaves the driver's seat.
4. This unit is equipped with a mechanical control lever
lockout. The brake lever must be disengaged before
control levers will move forward.
22
OPERATION INSTRUCTIONS
BLADE DRIVE SWITCH TEST
(ELECTRIC CLUTCH):
1. 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.
2. 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.
3. If any Safety Check fails, do not operate the mower
until the system has been checked and repaired by
an authorized Dixon ZTR dealer.
23
OPERATION INSTRUCTIONS
STARTING INSTRUCTIONS (cold engine):
1. Pull choke control lever up.
2. Push throttle control lever to 1/2 setting.
3. Insert ignition key and turn to “START” position.
When engine starts, release ignition key. Key will
return to “RUN” position.
4. Once engine starts to warm up, slowly push choke
control down to 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 ensure adequate lubrication, cooling and
cut quality of the mower deck.
Note:
24
Model ZTR 2560 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 the wide open or maximum setting for actual operation of the mower deck.
Note:
Model ZTR 2560 may require a 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 ensure adequate lubrication, cooling and
cut quality of the mower deck.
CAUTION
DO NOT operate the engine in an
enclosed area due to the harmful
exhaust gas produced.
Notes : On initial operation, set throttle at slow speed.
Engine cannot be restarted when blades are
engaged.
Safety switches stop engine when operator
leaves seat while mower blade is engaged.
Always turn engine off when leaving mower.
25
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
on Page 40-41.
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 taking 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. (Never attempt
to clean or service deck with engine running and/
or PTO engaged. This safety precaution must be
observed or serious injury could occur.)
5. Maintain Sharp Blade(s) hroughout The Cutting
Season.
26
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.
As a rule of thumb, never cut off more than 1/3 of the
total grass blade length. Correct mowing height can
reduce weeds and disease by 50% to 80%.
The following grass cut heights are based on adequate
moisture conditions and normal thatch build-up 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
Bermudagrass
Bluegrass
Buffalograss
Ryegrass
Tall Fescue
Zoysiagrass
Best Cut Heights
1 - 2”
2 - 3”
11/2 -3”
2 - 3”
3-31/2”
1 - 3”
27
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,
between the fuel tank and hydro pumps. To access
release valves, tilt seat plate forward. Use a 5/8”
wrench to rotate bolt counter-clockwise two full turns
to disengage pump. Repeat procedure for opposite
pump. To engage, rotate each pump bolt clockwise
until bolt is snug.
Note: Before pushing or towing tractor, the transmission must be unlocked, and parking brake
released. The tractor should never be pulled
at more than two miles per hour or for any
appreciable distance.
28
CARE AND MAINTENANCE
CAUTION
Before performing any maintenance, turn off engine,
allow to cool, remove key & 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 crankcase oil level.......................................before each use
•Clean grass from hydrostat fans & cooling fans.........before each use
•Clean grass & debris from muffler & manifold area.....before each use
•Check air intake screen...........................................after each use
•Clean grass under deck..........................................after each use
•Check tire pressure.................................................every 10 hours
•Check mower blades for sharpness.............................every 10 hours
•Clean air filter element..............................................every 25 hours
•Check hydrostatic transmission fluid............................every 25 hours
•Check all belts(20 hours break-in)...............................every 50 hours
•Grease all zerks......................................................every 50 hours
•Service air filter element.........................................every 100 hours
•Change engine crankcase oil............(5 hours break-in)every 100 hours
•Change engine oil filter.............................................every 200 hours
•Change hydrostat oil & oil filter.....(100 hours break-in)every 500 hours
•Replace air filter element..........................annually or every 500 hours
•Check spark plugs...................................annually or every 500 hours
29
CARE AND MAINTENANCE
ENGINE:
For complete maintenance and operating information of the
engine, please refer to the maintenance instructions furnished by
the engine manufacturer and included in your Zero Turn Radius
mower information packet.
Note:
Air intake screen must be kept clean. If plugged,
engine may be seriously damaged by overheating.
BATTERY:
CAUTION
Battery contains sulfuric acid electrolyte
which is poisonous and corrosive.
This is a maintenance-free battery and the fluid level cannot be
checked.
OFF SEASON BATTERY STORAGE:
DO NOT remove battery from mower.
Clean top of battery and terminals with baking soda and water.
Identify each cable so they can be reconnected to the correct terminal.
Disconnect cables from terminals. ALWAYS disconnect ground cable
first and reconnect last.
Charge battery.
TIRES:
Correct tire pressure is essential for efficient operation of the mower.
Check tire pressure periodically. Inflate tires to the pressure listed
below.
Front tires
Rear tires
-
12 lbs.
12 lbs.
Lug nuts or lug bolts should be checked regularly for tightness.
30
CARE AND MAINTENANCE
CAUTION
Stop engine and remove ignition key for safety.
Wear heavy, thick gloves when holding onto cutter
blade, avoid the sharp edge of the blade.
MOWER BLADES:
Check sharpness of mower blades after every 10 hours of operation.
To sharpen blades, proceed as follows.
1.
Remove bolt and flat washer mounting
blade on shaft. Remove blade.
2.
Blades should be discarded when worn
excessively.
3.
Sharpen blade with a hand file, electric
grinder or blade sharpener. Wear gloves
and eye protection when sharpening.
Grind blade at original 25 degree bevel.
4.
Check balance of blade by positioning the
blade on a nail or blade balance pedestal.
Grind the blade on the end that is heavier
until both sides balance.
5.
Install blade, flat washer & bolt. Make sure
to tighten bolt to 60 ft. lbs.
DANGEROUS!
DO NOT USE
BLADE IN THIS
CONDITION!
New Blade
When notch starts,
discard blade
31
CARE AND MAINTENANCE
LUBRICATION:
1. Engine: Follow engine manufacturer’s recommendation.
2. Deck spindles: Lubricate with 3 “shots” only, every
100 hours.
HYDROSTATIC TRANSMISSIONS:
Before each use, check to be sure that the cooling fins
and fans of the pumps and wheelmotors 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.
V-BELTS:
There are 3 v-belts on your Dixon Zero Turning Radius
Mower. They should be checked every 50 hours. Replace any
belts found to be in poor condition.
32
CARE AND MAINTENANCE
ELECTRICAL SYSTEMS:
Keep all connections clean and tight.
CLEANING THE MOWER:
Wash mower periodically. Clean above and below the
deck.
High pressure washing and alkaline based soaps can
cause damage to bearings and other parts of the mower.
After washing your mower, start the engine and engage
the mower deck for a few minutes to disperse any water
that may have accumulated in bearings, pulleys or fans.
Note: Allow mower to cool before washing. If bearings
are hot, they will draw moisture inside as they dry and
cause corrosion.
SERIAL NUMBERS:
The serial number is located on the frame at the rear of
the engine.
WARRANTY:
See information on Page 13 of this manual, or refer to
the Warranty Registration Form in your Owner’s Pack.
PARTS AND SERVICE:
See your Dixon Dealer for replacement parts, warranty or
service.
33
CARE AND MAINTENANCE
HYDROSTAT OIL MAINTENANCE PROCEDURE:
Check the oil level in hydrostatic transmisison oil reservoir after every 25 hours of usage. Clean the oil reservoir cap and the area around it prior to removal. Check
the oil level. Oil should be approximately 1-3/8” below
top of oil tank. Replenish as needed with SAE 20W-50
motor oil. DO NOT OVERFILL. When checking the oil
level, be very careful to keep the reservoir clean.
Change the oil in the reservoir and hydrostat transmission oil filter after the first 100 hours of use. Then
every 500 hours after that. Remove the filter and be
sure all oil has drained from the reservoir. Replace with
a new OEM filter (P/N 7252) and SAE 20W-50 motor oil.
Please dispose of used oil at proper collection centers protect your environment
34
CARE AND MAINTENANCE
PROCEDURE FOR RAISING AND LOWERING
THE DECK FOR SERVICING:
A . Move cut height adjustment lever to lowest
position.
B. Flip up the foot deck to allow access to the engine to deck drive belt. Roll the engine to deck
drive belt off the center spindle.
C . Lift the rear corner of the deck and remove 1/2”
x 1-1/2” clevis pin from lift link/eye bolt. Repeat
for the other side.
D . Position the front caster wheels so they are away
from the deck (such as the tractor would be
traveling in reverse).
E . Attach a hoist to the deck lift bolt. Lift the nose
of the deck until the deck is standing vertical and
the deck latch engages.
F. Reverse procedure for lowering deck.
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.
35
MOWER SHOWN IN OPERATIO N POSITION
CARE AND MAINTENANCE
36
MOWER SHOWN IN SERVICING POSITION
CARE AND MAINTENANCE
37
CARE AND MAINTENANCE
LEVELING THE DECK:
1. Set the tire pressure on all 4 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. Rotate the 2 outer spindles so the blades point outboard.
6. Adjust front hangers to level deck side to side, by
measuring at blade tips.
7. Rotate all 3 spindles until the blades are fore and aft.
8. Adjust rear hangers until deck is level to 1/4” higher
in the rear.
38
STANDARD SERVICE PARTS LIST
MODEL ZTR 2560:
Blades 60”
Hi-Lift (Standard)-P/N 12421
Low-lift-P/N 12451
Gator-P/N 12508
Belts
Engine to Mower Deck Belt-P/N 1300
Serpentine Belt 60”-P/N 9758
Engine to Hydro Belt-P/N 61778
Hydrostatic Transmission Filter-P/N 7252
KOHLER AIR AND OIL FILTER:
Refer to engine manufacturer’s manual for recommendations regarding frequency of service required for engine oil
changes and air filter maintenance.
Protect your engine investment, use only original equipment
filters.
IMPORTANT:
Some applications, extreme dirt conditions, or the use of a
grass catcher may require that the engine used on the
Model ZTR 2560 be fitted with an optional Kohler fresh air
filter system. Check with your engine service center for
availability.
39
TROUBLESHOOTING
1. ENGINE WON’T TURN OVER
Mower blades engaged- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - disengage blades
Blown fuse- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -replace fuse
Dead battery- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -charge or replace
Solenoid- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Ignition switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
Starter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Parking brake not set - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - engage parking brake
2. ENGINE WILL TURN OVER BUT WON’T START
No fuel- - - - - - - - - - - - - - - - - - - - - - - - - - - - -refuel and/or clean or replace fuel filters
Over or under choked- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -adjust choke
Spark plug not firing- - - - - - - - - - - - - - - - - - - - - - - -check spark plug/spark plug wires
Carburetor maladjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
Ignition switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
3. HARD TO START ENGINE
No fuel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - refuel and/or clean or replace fuel filters
Fuel line clogged- - - - - - - - - - - - - - - - - - - - - - - - - -clean fuel line and check fuel filter
Faulty fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Spark plug wire loose or grounded - - - - - - - - - - - - - - - - - - - - - check spark plug wires
Spark plug(s) faulty or improperly gapped- - - - - - - - - - - - - - - -check spark plug/regap
Electronic ignition defective- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
Dirty or maladjusted carburetor- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
4. ENGINE STARTS BUT CUTS OUT
Water in fuel- - - - - - - - - - - - - - - - - - - - - - - - - - - drain old fuel-replace with new fuel
Clogged fuel line- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - clean or replace fuel line
Fuel tank vent plugged- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - check vent and clean
Faulty fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - replace/consult dealer
Maladjusted carburetor- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
5. ENGINE KNOCKS
Low oil level- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - check and add oil
Fuel octane too low- - - - - - - - - - - - - - - - - - - - - - -replace with higher octane gasoline
Over heated engine- - - - - - - - - - - - -shut off engine and allow to cool/consult dealer
*see engine manual for engine adjustments
40
TROUBLESHOOTING
6. ENGINE OVERHEATED
Air intake screen or fins clogged- - - - - - - - - - - - - - - - - - -clean intake screen and fins
Oil level too low or too high- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -adjust oil level
Running engine too slow- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - run engine faster
Fuel mixture too lean- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
Improper ignition timing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
7. ENGINE RUNS BUT MOWER WON’T MOVE FORWARD
Drive belt broken or slipping- - - - - - - - - - - - - - - - - - - - - - - - - - - - - replace drive belt
Shift linkage disconnected- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -reconnect
Transmission shift arm disconnected- - - - - - - - - - - - - - - - - - - - - - - - - - -reconnect
Transmission oil low- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - add oil
Hydrostat oil filter plugged- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -replace filter
Damaged transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Free wheel feature activated- - - - - - - - - - - - - - - -put in unlock position (see Pg. 28)
8. MOWER LOSES POWER OR TRANSMISSION OVERHEATS
Hydrostat transmission oil too low or high- - - - - - - - - - - - - - add oil or drain as needed
Transmission damage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Transmission blowing oil out cap- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
9. ENGINE STALLS WHEN BLADES ARE ENGAGED
Operator not on seat- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - sit on seat
Faulty interlock system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Damaged blade spindle bearing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
Deck drive belt not properly routed- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - reroute
Blades blocked by foreign material- - - - - - - - - - - - - - - - - - - - - - - - - -clean under deck
10. ENGINE SOMETIMES SKIPS AT HIGHER SPEEDS
Incorrect ignition timing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Carburetor maladjusted- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
Faulty spark plugs- - - - - - - - - - - - - - - - - check spark plug or condition and reset gap*
11. ENGINE IDLES POORLY
Carburetor maladjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
Improper spark plug gap- - - - - - - - - - - - - - - - - - - - - - - - - - check and reset gap*
12. ENGINE BACKFIRES
Carburetor maladjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
*see engine manual for engine adjustments
41
NOTES
42
OWNER
INFORMATION
DIXON INDUSTRIES, INC.
a BLOUNT International Inc. Co.
P.O. Box 1569
Coffeyville, Ks 67337-0945
620-251-2000
FAX 620-251-4117
Date Purchased _________________________________
Mower Model Number__________________________
Mower Serial Number ____________________________
Purchased From ________________________________
Name
________________________________
Address
______________________________
DATE OIL CHANGED:
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
DATE ENGINE TUNED:
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
___________________
43
ZTR®Mowers
WARNING:
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm.
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
Model 2560
Part No. 61935-0603
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