Dixon 8000D Lawn Mower User Manual

8000D SERIES
OPERATOR’S MANUAL
2003
IMPORTANT - READ CAREFULLY
The Dixon® ZTR® Mower is both easy and fun to operate.
However, any power mower must be operated properly to be
safe. It is not a toy or a recreational vehicle. Before you
start to use the mower, read the operator’s manual carefully
and become completely familiar with the controls.
The information contained in this manual applies to all
Dixon® ZTR® 8000 Series (Diesel Version) Commercial
Mowers. Your Dixon dealer will gladly answer any questions.
See your dealer for warranty service, parts and repairs.
INDEX
Page
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-18
Operation Instructions. . . . . . . . . . . . . . . . . . . 19-26
Care & Maintenance. . . . . . . . . . . . . . . . . . . . . .27-39
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 40-41
Standard Service Parts List. . . . . . . . . . . . . . . . . . . .42
8000 Series (Diesel)
Part No. 13638-xxxx
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 crossingroadways.
•Use extra care when loading or unloading the mower into a
trailer or truck. Do not ride the mower when loading and
unloading.
•Always wear safety goggles or safety glasses with side
shields when operating mower.
•Data indicates that operators, age 60 years and above, are
involved in a large percentage of riding mower-related
injuries. These operators should evaluate their ability to
operate the riding mower safely enough to protect
themselves and others from serious injury.
•Follow the manufacturer’s recommendation for wheel
weights and counterweights.
•Maintain or replace safety & instruction labels as needed.
WARNING:
The engine exhaust from this product contains chemicals known to the State of
California to cause cancer, birth defects or other reproductive harm.
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.
•
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.
•
8
Do not use grass catcher on steep slopes.
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.
9
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.
10
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 buildup. Clean
up oil or fuel spillage. Allow mower to cool before storing.
•
Stop and inspect the equipment if you strike an object. Repair,
if necessary, before restarting.
•
Never make adjustments or repairs with the engine running
unless otherwise specified.
•
Grass catcher components are subject to wear, damage and
deterioration, which could expose moving parts or allow objects
to be thrown. Frequently check components and replace with
original equipment parts, when necessary.
•
Mower blades are sharp and can cut. Wrap the blade(s) or wear
gloves, and use extra caution when servicing them.
•
Batteries contain sulfuric acid. To prevent burns avoid contact
with skin, eyes and clothing. To prevent a fire or explosion keep
sparks and open flames away from battery.
•
Before disconnecting the negative (-) ground cable, make sure all
switches are OFF.
11
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 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 &accessories.
2. All Dixon warranty must be accomplished by authorized Dixon dealers and in accordance with Dixon
warranty policy and allowances. All warranty claims must be approved by Dixon Industries, Inc.
3. Battery warranty: Limited to 90 days from date of purchase.
4. Accessories Warranty (Grass Catchers, Snow Blades, Covers, etc.): Limited to 90 days from date of
purchase.
5. Warranty does not apply to damage in transit or incidents of misuse, negligence, accidents, or
alteration. The use of parts or components other than those supplied by Dixon Industries, Inc. VOIDS
ALL WARRANTY.
6. The following items are not covered by this warranty policy:
a.
Pick up and delivery charges for transportation of mower to and from an authorized Dixon
dealer’s place of business.
b.
Routine maintenance or adjustments.
c.
Belts/cutting blades/hydrostatic filters.
d.
Engines - All engines used on Dixon ZTR mowers are warranted by the individual engine
manufacturer.
e.
Any costs or expense of providing substitute equipment while repair work is being
performed on a warranted mower.
7. There is no other express warranty. Implied warranties, including those of merchantability and fitness
for a particular purpose, are limited to the same duration of the express warranty, and to the extent
permitted by law any and all implied warranties are excluded. Liabilities for consequential damages
under any and all warranties are excluded.
Blue/Customer
Yellow/Dealer
White/Dixon Ind.
WARRANTY VALIDATION: At the time of sale, selling dealer must review each portion of this
warranty document, complete the information section below, secure customer’s signature &
send copy to Dixon Industries, Inc.
DATE OF PURCHASE____________________MODEL___________________S/N_______________
_____________________________________
______________________________________
Owner’s Name
Dealership
_____________________________________
______________________________________
Address
Address
______________________________________
_______________________________________
_____________________________
______________________________
Owner’s Signature
Dealer’s Signature
12
SPECIFICATIONS
8000 Series (Diesel Version)
CHASSIS:
11 GA - rectangular tube, 7 GA reinforcement
SEAT:
Designed for operator comfort with padded back & arm rests.
Seat is adjustable fore & aft. Mounted on operator suspension
system with damper.
MOWER DECK:
2 decks are available. Both are made of 10 GA fabricated welded
construction with 1/4” reinforcement plate. 3 blades combine for
either a 60” or 72” cut width. Deep deck with discharge tunnel.
Cut height approximately 1.5” to 6” via 10 position lift handle.
BLADE DRIVE:
“V” belt with electric clutch
DRIVE SYSTEM:
Each rear wheel is independently driven by a Hydro-Gear BDP-21L
pump and White CE wheel motor.
ENGINE:
26 HP Briggs & Stratton Vanguard 950D, 3 cylinder in-line, water
cooled, diesel, horizontal shaft, pressure feed lubrication with spinon oil filter, fuel filter with primer pump and water separator,
paper element with cyclone pre-cleaner.
STARTING
SYSTEM:
Electric by key switch operation with safety interlocks on parking
brake, blade drive clutch and control levers.
TIRES:
Front
Rear
13-6.5x6
23-10.5x12
RECOMMENDED
TIRE PRESSURE:
Front
Rear
16-20 lbs.
8-14 lbs.
CAPACITIES:
Fuel - 11 gallons (approximate)
Hydrostat oil system - 4 quart with in-line 25 micron filter
Hydrostat oil recommendation - SAE 20W50 motor oil
Engine - 3.5 quart CF/CF4 10W30 motor oil
Coolant capacity - 2 gallons 50/50 mix
DIMENSIONS:
Width
73.5” (60” Deck), 85.5” (72” Deck)
Height 54”
Length 93”
Weight 1330 lbs (60” Deck), 1364 lbs. (72” Deck)
Additional information provided in service instructions under the individual component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
13
CONTROLS
CONTROL LEVERS:
Note:
For access to the seat, move control levers to neutral position and
swing them outward.
TO GO FORWARD:
•From neutral position, gently push both control levers forward.
•To increase speed, move levers further forward.
TO GO BACKWARD:
•From neutral position, gently pull both control levers toward you.
TURNING:
•Turning is controlled by moving one control lever slightly forward or
rearward of the other.
•To turn left, move left lever rearward of the right lever.
•To turn right, move right lever rearward of the left lever.
•To turn on mower’s own axis (zero turning radius), stop and move one
lever to reverse position and the other to forward position.
BRAKING:
•To brake mower, move both levers in direction opposite of travel.
LEFT TURN OPPOSITE
Note: The pressure required to operate the mower is very light.
14
CONTROLS
PARKING BRAKE:
A parking brake is located to the left of the seat.
The engine will kill if control levers are not in the
outboard position when the parking brake is engaged.
To engage brake: pull up and back
To disengage brake: push forward and down
Note: The parking brake is not intended to be used
as a service brake.
Note: Always set parking brake before dismounting.
Release the parking brake before moving mower.
Note: Engage parking brake before starting engine.
MOWER DECK LIFT:
The mower lift lever is extra long & has an assist
spring for easy operation.
1)
2)
3)
Grasp lever with right hand.
Depress thumb lever to release. Move to
desired position.
Release lever to lock into position.
Select cut height & insert pin into first hole below the
lift lever. Ten holes are provided for a down stop so
you can easily return from transport to desired cut
height.
15
CONTROLS
SEAT:
Fore & Aft: Move lever, slide seat fore & aft to
desired position. Release.
Seat Damper: A shock is located on the left side
of the seat frame. Remove clip on the top and
pull plunger up. Rotate shaft clockwise to make
ride stiffer and counter-clockwise for a softer ride.
Reattach to seat frame with clip.
Attention: Do not completely close off the
damper. Closing off the damper causes it to
become stiff making it difficult to fully extend the
damper in order to open the adjustment. THE
PRODUCT IS NOT DAMAGED. To restore
adjustment follow these instructions: Hang the
damper in the vertical position with the rod
pointing down. Attach a load of approximately
15 pounds to the rod end of the damper. The
load will slowly extend the damper. When fully
extended the adjustment pin will be engaged.
Turn rod with the weight still hanging to open
the adjustment.
16
CONTROLS
MOWER BLADE SWITCH:
To engage blades: pull up on switch
To disengage blades: push down
IGNITION SWITCH:
•Turn to run position to energize glow
plugs.
•Turn to start position when glow plug
light turns off, then 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.
THROTTLE CONTROL LEVER:
•Located on control panel to operator’s right.
•Controls engine speed.
•While mowing, throttle control should be set to MAXIMUM or wide
open setting to insure adequate cooling of the engine and to maintain
mower deck blade speed.
CIRCUIT BREAKER:
•If circuit breaker pops up, it disconnects the power. Wait 2 minutes
then pull up and push to reset.
•If it pops up again, there is a short circuit. Stop and find fault or
contact your dealer.
GLOW PLUG LIGHT:
•Light is energized when ignition switch is first put in run position. Glow
light cycle time is five seconds.
WATER IN FUEL LIGHT:
•Light comes on when engine is running and fuel has water in it.
17
CONTROLS
18
OPERATION INSTRUCTIONS
The safe and successful operation of the 8000 Series Diesel Version
will depend upon the operator having the correct knowledge of all
controls used on the mower and making good judgements about the
terrain to be mowed.
NEVER allow anyone to operate the mower without complete
knowledge of all controls and their functions.
During initial operation, “learning to drive”, set throttle at slow speed.
BEFORE OPERATING MOWER:
1.
Read and observe all safety instructions on your
mower and in the manual.
2.
Read engine manufacturer’s operating and
maintenance instructions.
3.
Check engine oil.
4.
Check fuel cap to be sure it is in place.
5.
Be sure parking brake is on.
6.
Mower blade drive is off.
7.
Know how to stop engine. (Turn key to off position).
19
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.
20
1.
The engine will not start if the mower blades are
engaged.
2.
The engine will not start unless the steering control
levers are neutral “OUT” position.
3.
The engine will stop if the mower blade clutch is
engaged and the operator leaves the driver’s seat.
4.
The engine will stop if the park brake is ON and the
steering control levers are moved to the “IN” position.
OPERATION INSTRUCTIONS
INTERLOCK SWITCH TEST:
Note: Operator must be seated in normal operating position to
perform these tests.
1.
With engine off, turn mower blade on and attempt to
start engine.
ENGINE SHOULD NOT START.
2.
With engine off, move control levers in and attempt to
start engine.
ENGINE SHOULD NOT START
3.
In a SAFE AREA, away from bystanders, start the
engine, place throttle setting at maximum or full.
Engage the blade drive through the electric clutch
switch. Raise slightly off of seat.
ENGINE SHOULD STOP.
4.
With engine running, set parking brake and move
levers inboard.
ENGINE SHOULD STOP.
If any safety check fails, do not operate the mower until the
system has been checked and repaired by an authorized
Dixon ZTR dealer.
21
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 slow setting.
6.
Insert ignition key and turn to run position.
Glow plug should light.
7.
When glow plug light goes off, turn ignition
key to “start” position. When engine starts,
release ignition key. Key will return to “run”
position.
8.
Let engine warm up a few minutes then move
throttle control lever to the wide open or
maximum setting for actual operation of the
mower deck. Engine must be operated at wide
open or maximum setting to insure adequate
lubrication, cooling and cut quality of the
mower deck.
CAUTION
Do not operate the engine in an enclosed
area due to the harmful exhaust gas
produced.
STOPPING INSTRUCTIONS:
22
1.
Turn mower blades off.
2.
Move control levers to outboard position.
3.
Set parking brake.
4.
Move throttle control to slow. Allow engine to run a
short time to cool down then turn ignition key to “OFF”
and remove key.
OPERATION INSTRUCTIONS
MOWING INSTRUCTIONS:
CAUTION
1.
2.
3.
Be sure that deflector is properly
installed on the discharge chute.
Start engine and set throttle at full
speed.
Set desired cut height.
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 instructions on Page 14.
23
OPERATION INSTRUCTIONS
GRASS HEIGHT AND CUTTING SUGGESTIONS:
Do not attempt to cut grass when it is wet.
If the grass is tall, place the mower deck cut height
lever in the top or second notch. “Initially” overlap
cutting swaths instead of a full swath with each pass.
Some applications may require a second cutting.
Keep the underside of the mower deck clean.
Maintain sharp blades throughout the cutting season.
As a rule of thumb, never cut off more than 1/3 of the
total grass blade length.
Correct mowing height can reduce weeds and disease
by 50% to 80%.
The following grass cut heights are based an adequate
moisture conditions and normal thatch buildup in a
healthy lawn. Some locations and applications may
require slightly different cut heights. If in doubt, consult
your local lawn professional for assistance.
Grass Types
Bermudagrass
Bluegrass
Buffalograss
Ryegrass
Tall Fescue
Zoysiagrass
24
Best Cut Heights
1 - 2”
2 - 3”
11/2 -3”
2 - 3”
3-31/2”
1 - 3”
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 to lock them in place.
Release the seat latch and rotate the counter-balanced
seat support frame upward and forward.
To return the seat to the operating position, push the
counter-balanced seat frame support rearward and
down until it rests firmly on the tractor frame. Reconnect
the seat damper by reversing the order of removal as
stated above.
SPRINGS:
Three seat springs are provided. The center spring may
be removed for a softer ride.
25
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 right side of the hydro pump on each side of the
machine. To unlock the transmission, lift the seat (see
instructions on Page 25), rotate the transmission hex
valve located on the top of each transmission approximately one turn counter-clockwise.
To re-engage the transmission, rotate each transmission hex valve clockwise to the end of its travel. Return
the seat to the operating position.
Note: Before pushing or towing the tractor, the transmission must be unlocked and the parking brake
released. The tractor should never be pulled
more than two miles per hour or for any appreciable distance.
26
CARE AND MAINTENANCE
CAUTION
Before
perfor
orming
anyy maintenance
maintenance,, tur
turn
engine,,
Bef
ore perf
or
ming an
n off engine
allow to cool & remo
ve
key
.
remove key.
machineryy.
Use extreme care when working on machiner
watch
jewelryy. Do not wear loose ffitting
clothes,,
Do not wear wa
tch or jewelr
itting clothes
observe
tools..
and obser
ve all common safety practices with tools
MAINTENANCE SCHEDULE
•Check deck drive belt tension adjustment......................................after 5 hours break-in
(adjust spring tension to 7to7-1/2inside to inside spring hook
dimension. Check belt tension periodically. Adjustments as necessary)
•Check deck serpentine belt............................................................after 20 hours break-in
(adjust bumper to approximately 1/2” thick)
• Check crankcase oil level..........................................................before each use
•Clean grass from hydrostat fans, radiator & radiator screen...............before each use
•Clean grass & debris from muffler & manifold area................................before each use
•Check coolant level in reservoir....................................................................before each use
•Check air intake screen.....................................................................................after each use
•Clean grass under deck.....................................................................................after each use
•Check tire pressure...................................................................................every 10 hours
•Inspect blades for sharpness.............................................................................every 10 hours
•Clean air filter element.........................................................................................every 25 hours
•Check hydrostatic transmission fluid..................................................................every 25 hours
•Grease all zerks.....................................................................................................every 50 hours
•Check drive and fan belt.......................................................................................every 50 hours
•Replace air filter element.............................................................annually or every 100 hours
•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
•Change coolant.................................................................................................................annually
27
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.
Note:
Clean radiator chaff screen when it becomes
covered during operation.
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 correct the
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
-
16-20 lbs.
8-14 lbs.
Lug nuts or lug bolts should be checked regularly for tightness.
28
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
BELTS:
When notch starts,
discard blade
Check belts every 50 hours. Replace any belts found to
be in poor condition.
29
CARE AND MAINTENANCE
LUBRICATION:
30
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).
CARE AND MAINTENANCE
CHECKING & REPLENISHING OIL IN HYDROSTATIC
TRANSMISSION:
Dirt or water in oil can ruin the
hydrostatic transmissions.
Check the oil level in hydrostatic transmission oil
reservoir after every 25 hours of usage. Clean the oil
reservoir cap and the area around it prior to removal.
Check the oil level. Oil should be approximately 1-3/8”
below top of oil tank. Replenish as needed with
SAE 20W-50 motor oil. DO NOT OVERFILL. When
checking the oil level, be very careful to keep the
reservoir clean.
Change the oil in the reservoir and hydrostat
transmission oil filter after the first 100 hours of use.
Then every 500 hours after that. Remove the filter
and be sure all oil has drained from the reservoir.
Replace with new filter and SAE 20W-50 motor oil.
Please dispose of used oil at proper collection centers protect your environment
31
CARE AND MAINTENANCE
PARKING BRAKE ADJUSTMENT:
32
1.
Loosen the locking screw on the top knob of
the brake engaging handle.
2.
Rotate it clockwise to increase and counterclockwise to decrease brake holding power.
As the brake holding power is increased, the
force required on the handle to engage the
brake increases.
3.
Set the brake for the holding power required
for the intended use and the desired force
required to activate it.
4.
Retighten the knob locking screw.
CARE AND MAINTENANCE
HEADLIGHT ADJUSTMENT:
1.
Loosen the 1/2” retaining nut underneath the
headlight and slide the headlight forward out of
the fuel tank.
2.
Loosen the 1/2” nut on the “U” shaped
holding bracket and swivel the headlight vertically
to adjust the height of the beam. Tighten the
bracket nut.
3.
Replace headlight in fuel tank.
4.
Swivel the headlight horizontally to illuminate the
desired area and tighten the headlight retaining
nut.
33
CARE AND MAINTENANCE
HYDROSTATIC PUMPS:
Before each use, check to be sure that the cooling fins
of the hydrostatic pumps are clean. Excessive
accumulation of oil, dirt, or trash may cause the pumps
to overheat. NEVER WASH ACROSS TOP OF RESERVOIR
WITH WATER OR STEAM. Fill reservoir as required per
the maintenance schedule listed in this book
HYDROSTAT DRIVE BELT
REPLACEMENT PROCEDURE (continued):
To remove hydrostat pump drive belt:
(The hydrostat pump drive is equipped with a spring
loaded belt take-up)
1.
2.
3.
4.
5.
6.
7.
34
Raise seat.
Drain radiator.
Remove radiator mounting hardware and hoses.
Remove radiator.
Remove double u-joint flange bolts and remove
double u-joint.
Rotate the spring loaded take-up idler toward the
left hand hydro pump to provide belt slack for
removal.
Remove belt.
CARE AND MAINTENANCE
HYDROSTAT DRIVE BELT
REPLACEMENT PROCEDURE:
To install hydrostat pump drive belt:
1.
Rotate the spring loaded take-up idler towards
the left hand hydro pump.
2.
Install belt per diagram.
3.
Install double u-joint and tighten flange bolts
(tighten to 14 ft. lbs.).
4.
Install radiator and mounting hardware.
5.
Attach radiator hoses and refill cooling system.
35
CARE AND MAINTENANCE
STEERING CONTROL ADJUSTMENTS:
To adjust neutral:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Lift seat (see instructions on Page 16).
Block up the unit so that the drive wheels are off
the ground.
Loosen ball joint jam nuts on control rod.
Note: The front jam nuts are left hand threads.
With steering control arms in the “out” neutral
position, start the engine and run at fast idle.
Adjust the neutral position by turning the control
rod until the wheels do not rotate.
Retighten the jam nuts on the control rod and
check to see that the drive wheels are not turning.
Repeat steps 3-6 for the other side.
Shut off engine before removing the blocks.
Return the seat to the operating position.
To adjust neutral springs:
1.
2.
3.
4.
5.
6.
36
Loosen set screws of front and rear spring stop
collars located on the control rods. (requires a
1/8” Allen wrench)
Move control handle full forward.
Move front spring stop collar rearward until it
compresses spring approximately 1/16” and
tighten collar set screw.
Move control handle full rearward.
Move rear spring stop collar forward until it
compresses spring approximately 1/16” and
tighten collar set screw.
Repeat steps 1-5 for opposite side.
CARE AND MAINTENANCE
STEERING CONTROL ADJUSTMENTS (continued):
To adjust steering control levers:
1.
2.
3.
4.
5.
6.
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.
Move the levers inboard to the operating position.
Loosen the set screw of the clamp collars which
lock the upper arms to the lower arms.
Raise or lower the arms for desired height.
There is approximately 3” of height adjustment
available. Upper shaft should have a minimum
of 1-1/2” engagement in lower shaft.
Rotate the arms until they have the desired
orientation front to back.
Tighten the clamp collar set screws.
37
CARE AND MAINTENANCE
STEERING CONTROL ADJUSTMENTS (continued):
To adjust “In” position of the steering controls:
1.
Move the levers inboard to the operating position.
Adjust the steering lever stops until the steering
levers have the desired clearance.
To adjust for straight forward tracking:
1.
2.
3.
Drive tractor with both control levers in the full
forward position.
Stop the machine and shut off the engine.
Adjust the forward stop of the control lever on
the side which appears to be faster to limit the
forward travel of the control levers until the
mower tracks in a straight line.
Note: Variations in the turf and tire pressure
can cause variations in speed and
tracking.
When all alignment adjustments are satisfactory, slide
the hold down plate and bellows down the control levers
and secure with screws.
38
CARE AND MAINTENANCE
LEVELING THE DECK:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Set the tire pressure on all four tires.
Front casters must be rotated in the direction of
forward travel.
Move the tractor to a hard level surface.
Put the mower deck in the number 3 deck height
position.
Loosen the jam nuts on the front and rear deck
hangers.
Rotate the 2 outer spindles so the blades point
outboard.
Adjust front hangers to level deck side to side.
Rotate all 3 spindles until the blades are fore
and aft.
Adjust rear hangers until deck is level to 1/8
higher in the rear.
Retighten the jam nuts on the front and rear deck
hangers.
39
TROUBLESHOOTING
1.
ENGINE WON’T TURN OVER
Mower blades engaged- - - - - - - - - - - - - - - - - - - - - - -disengage blades
Drive not in neutral - - - - - - -move control levers to neutral “OUT”
Circuit breaker trips - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - reset
Dead battery- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - charge or replace
Solenoid- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Ignition switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Starter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Parking brake not on- - - - - - - - - - - - - - - - - - - - -engage parking brake
2.
ENGINE WILL TURN OVER BUT WON’T START
No fuel- - fuel and/or clean or replace fuel filters/open fuel vavle
3.
HARD TO START ENGINE
Fuel line clogged- -clean fuel line/check fuel filter/open fuel vavlve
Faulty fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
4.
ENGINE STARTS BUT CUTS OUT
Water in fuel- - - - - - - - - - - - - - - -drain old fuel-replace with new fuel
Clogged fuel line- - - - - - - - - - - - - - - - - - - - check fuel filterclean fuel line
Fuel tank vent plugged- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - check vent
Faulty fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
Engine dies when control levers moved “IN”-release parking brake
*see engine manual for engine adjustments
40
TROUBLESHOOTING
5.
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
Low coolant level- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -add coolant
Grass & debris on chaff screen- - - - - - - - - - - - - - - - - - - - clean screen
6.
ENGINE RUNS BUT MOWER WON’T MOVE FORWARD
Drive belt broken or slipping- - - - - - - - - - - - - - - - - - - -replace drive belt
Shift linkage cable disconnected- - - - - - - - - - - - - - - - - - - - - - reconnect
Transmission shift arm disconnected- - - - - - - - - - - - - - - - reconnect
Transmission oil low- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - add oil
Transmission locks in free wheel position-- - - - - - - - - - - - - - see pg.26
Hydrostat oil filter plugged- - - - - - - - - - - - - - - - - - - - - - - - - - -replace filter
Bad transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
Gear mating transmission/gearbox disconnected- - consult dealer
7.
MOWER LOSES POWER OR TRANSMISSION OVERHEATS
Hydrostat transmission oil too low or high- - - - - -add or drain oil
Transmission damage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
Transmission blowing oil out cap-- - -overfilled or water contaminated
8.
ENGINE STALLS WHEN BLADES ARE ENGAGED
Operator not on seat- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -sit on seat
Faulty interlock system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
Bad Blade spindle bearing- - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Deck drive belt not properly routed- - - - - - - - - - - - - - - - - - - - - - - reroute
Blades blocked by foreign material- - - - - - - - - - - - - - clean under deck
*see engine manual for engine adjustments
41
STANDARD SERVICE PARTS LIST
MODEL ZTR 8026D:
Blades (60”):
Blades (72”):
Engine to Mower Deck Belt:
Serpentine Belt (60”):
Serpentine Belt (72”):
Engine to Hydro Belt:
Hydrostatic Transmission Filter:
P/N 12421
P/N 12339
P/N 12503
P/N 9758
P/N 12033
P/N 12012
P/N 7252
BRIGGS & STRATTON AIR AND OIL FILTER
PART NUMBERS:
Refer to engine manufacturers manual for recommendations regarding frequency of service required for
engine oil changes and air filter maintenance.
Protect your engine investment, use only original
equipment filters.
Model ZTR 8026D (26 HP):
Air Filter
Engine Oil Filter
13480
13481
IMPORTANT:
Some applications, extreme dirt conditions, or the use
of a grass catcher may require that the engine used on
the Model ZTR 8026D be fitted with an optional Briggs
& Stratton fresh air filter system. Check with your
engine service center for availability.
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
8000 Series (Diesel)
Model 8026D
Part No. 13638-xxxx