ZTR®
OPERATOR’S MANUAL
2003
INDEX
Page
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . .14
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-18
Operation Instructions. . . . . . . . . . . . . . . . . . . 19-26
Care & Maintenance. . . . . . . . . . . . . . . . . . . . . .27-35
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 36-37
Standard Service Parts List. . . . . . . . . . . . . . . . . . . .38
7500 Series
Part No. 13636-0702
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
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.
The engine exhaust from this product contains chemicals known to the
State of California to cause cancer, birth defects or other reproductive
WARNING:
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.
Do not use grass catcher on steep slopes.
•
•
•
8
SAFETY
CHILDREN:
Tragic accidents can occur if the operator is
not alert to the presence of children.
Children are attracted to lawn mowers
and the mowing activity.
NEVER assume children will stay
where they were last seen.
Be alert to avoid accidents.
•
Keep children out of the mowing area and
under the watchful care of another responsible
adult.
•
•
•
Be alert and turn mower off if a child enters
the area.
Before and during backing, look BEHIND and
DOWN for small children.
Never carry children. They may fall off and be
seriously injured or interfere with safe mower
operation.
•
•
Never allow children to operate the mower.
Use extra care when approaching blind
corners, shrubs, trees, or other objects that
may obscure vision.
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 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.
11
DIXON LIMITED WARRANTY POLICY - HYDRO GEAR MODELS
5000 - 6000 - 7000 Series Mowers
WARRANTY: Dixon Commercial Warranty is for a period of one (1) year from date of purchase
or 400 hours of use, whichever occurs first. Mowers used for Homeowner Application (used only
at owner’s primary place of residence) are warranted for two (2) years from date of purchase.
DIXON ZTR MOWERS ARE WARRANTED AGAINST DEFECTS IN MATERIALS AND
WORKMANSHIP AND PROVIDES FOR REPLACEMENT OR REPAIR OF PARTS INCLUDING LABOR
COSTS. THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS AND LIMITATIONS:
1.
Warranty applies only to original retail purchaser of new and unused mowers and
accessories.
2.
All Dixon warranty must be accomplished by authorized Dixon dealers and in
accordance with Dixon warranty policy and allowances. All warranty claims must be
approved by Dixon Industries, Inc.
3.
4.
Battery warranty: Limited to 90 days from date of purchase.
Accessories Warranty (Grass Catchers, Snow Blades, Covers, etc.): Limited to 90
days from date of purchase.
5.
6.
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.
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 ofproviding 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.
Copies: Pink/Customer
Yellow/Dealer
White/Return to 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 and
send copy to Dixon Industries, Inc.
Date of Purchase
Model
Deck Size
S/N
(Owner's Name)
(Street Address)
(City/State/Zip)
(Dealership Name & Dealer Number)
(Street Address)
(City/State/Zip)
(Owner's Signature)
(Dealer's Signature)
DIXON INDUSTRIES, INC.
A BLOUNT International Inc. Co.
PO BOX 1569
COFFEYVILLE KS 67337 0945
PHONE 620 251 2000
1-877-CUT-MORE
FAX 620 251 4117
12
SPECIFICATIONS
7500 Series
CHASSIS:
BODY:
Folded sheet metal and rectangular tube
Folded sheet metal
SEAT:
Designed for operator comfort with 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 HydroGear HGM-15E 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 12 lbs.
TIRE PRESSURE: Rear 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 69-1/2"
Height 43"
Length 81”
Weight 916 lbs.
Additional information provided in service instructions under the individual component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
13
SEAT ADJUSTMENT INSTRUCTIONS
Model 7525
1.
Grasp seat slide adjuster and move it into
adjustment position.
2.
3.
Slide seat forward or backward.
Release seat slide adjuster.
Seat Slide Adjuster
14
CONTROLS
15
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.
16
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: Always set parking brake before dismounting. Release
the parking brake before moving mower.
Note: Engage parking brake before starting engine.
HYDRO-GEAR DRIVE SYSTEM:
Allows the mower to turn on its own axis (zero turning radius).
Each lever controls one side of the mower.
NOTE: The pressure required to operate the mower is very light.
17
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.
18
OPERATION INSTRUCTIONS
The safe and successful operation of the ZTR 7500
Series will depend upon the operator having the correct
knowledge of all controls used on the mower and
making good judgements about the terrain to be
mowed.
NEVER allow anyone to operate the mower without
complete knowledge of all controls and their functions.
During initial operation, “learning to drive”, set throttle
at slow speed.
Sound judgement by the owner will prevent accidents.
BEFORE OPERATING MOWER:
1.
Read and observe all safety instructions on
your mower and in the manual.
2.
Read engine manufacturer’s operating and
maintenance instructions.
3.
4.
5.
6.
7.
8.
Discuss proper maintenance with your dealer.
Check engine oil.
Check fuel cap to be sure it is in place.
Be sure parking brake is on.
Mower blade drive is off.
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.
1.
2.
3.
The mower blades must be disengaged before
the engine will start.
The brake lever must be engaged (upward
position) before engine will start.
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.
20
OPERATION INSTRUCTIONS
BLADE DRIVE SWITCH TEST (ELECTRIC CLUTCH):
1.
2,
3.
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.
In a safe area, away from bystandards, 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.
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 (cold engine):
1.
2.
3.
Pull choke control lever up.
Push throttle control lever to 1/2 setting.
Insert ignition key and turn to “START” position.
When engine starts, release ignition key. Key
will return to “RUN” position.
4.
5.
Once engine starts to warm up, slowly push
choke control lever down to fully closed position.
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: Model ZTR 7525 will require a slightly longer
warm up period using partial choke settings.
22
OPERATION INSTRUCTIONS
STARTING INSTRUCTIONS(engine has been operated):
1.
2.
Move throttle control lever to 1/4 to 1/2 setting.
Insert ignition key and turn to “START” position.
When engine starts, release ignition key. Key
will return to “RUN” position.
3.
4.
Move throttle control lever to the wide open or
maximum setting for actual operation of the
mower deck.
Note: Model ZTR 7525 may require a partial
choke setting to start even if the engine
has been operated for a period of time.
Engine must be operated at wide open or
maximum setting to ensure adequate lubrication,
cooling and cut quality of the mower deck.
DO NOT operate the engine in an
CAUTION
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.
23
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 36-37.
CAUTION Be sure that deflector is properly installed
on the discharge chute.
1.
2.
Set engine speed control to the wide open or full
setting.
Do Not Attempt To Cut Grass When It Is Wet.
Wet grass will clog the underside of the deck
and discharge area.
3.
4.
If the grass is tall, place the mower deck cut height
lever inthe top or second notch. “Initially” overlap
cutting swaths instead of taking a full swathwith
each pass. Some applications may require a
second cutting.
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) Throughout The Cutting
Season.
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.
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”
”
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 behind the seat,
between the fuel tank and hydro pumps. Use a 5/8”
wrench and insert through the slots on the top side of the
seat plate and 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 transmis-
sion must be unlocked, and parking brake re-
leased. The tractor should never be pulled at
more than two miles per hour or for any appre-
ciable distance.
26
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
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.
BATTERY:
Battery contains sulfuric acid electrolyte
which is poisonous and corrosive.
CAUTION
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.
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.
3.
Blades should be discarded when
worn excessively.
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.
5.
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.
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
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.
29
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.
30
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
31
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. Hook the engine
to deck drive belt onto the bolt protruding out of
the top of the foot deck support angle.
C.
D.
E.
F.
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.
Position the front caster wheels so they are
away from the deck (such as the tractor would
be traveling in reverse).
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.
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.
32
CARE AND MAINTENANCE
LEVELING THE DECK:
A.
B.
Set the tire pressure on all four tires.
Move the tractor to a hard, level surface (i.e.
concrete or blacktop). Place a 2x4 board under
all four corners of the deck shell, just inside the
anti-scalping wheels. Lower the deck down onto
the boards. The deck must rest on the boards,
not on the anti-scalping wheels. Adjust the deck
hangers longer or shorter until the deck “just”
comes off of the boards in front. Raise the rear
1/4” above the boards. Remove the boards and
verify that the deck is hanging on all four deck
hangers, re-adjust if necessary. Lock the jam nuts
on the deck hangers. (Note: the two rear deck
hangers will be easier to adjust if the fender skirts
are removed.)
CARE AND MAINTENANCE
34
MOWER SHOWN IN SERVICING POSITION
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.
3.
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 wires
Carburetor maladjustment- - - - - - - - - - - - - - - - - - - - - - -- -- readjust carburetor/consult dealer
Ignition switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - readjust carburetor/consult dealer
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
Electronic ignition defective- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
Dirty or maladjusted carburetor- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
4.
5.
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
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
36
TROUBLESHOOTING
6.
7.
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
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
Hydrostat oil filter plugged- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - replace filter
Damaged transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Gear mating transmission/gearbox disconnected- - - - - - - - - - - - - - - - - - - - - - - -consult dealer
Free wheel feature activated- - - - - - - - - - - - - - - - - - - - - - - -put in unlock position (see Pg. 26)
8.
9.
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- - - - - - - - - - - - - - - - - - - - - - - -overfilled or water contaminated
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.
12.
ENGINE IDLES POORLY
Carburetor maladjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consultdealer
Improper spark plug gap- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -check and reset gap*
ENGINE BACKFIRES
Carburetor maladjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consultdealer
*see engine manual for engine adjustments
37
STANDARD SERVICE PARTS LIST
MODEL ZTR 7525:
Blades 60” Hi-Lift:
Blades 60” Lo-Lift:
Engine to Mower Deck Belt:
Serpentine Belt 60”:
Engine to Hydro Belt:
P/N 60295
P/N 60293
P/N 61515
P/N 61512
P/N 61778
P/N 7252
Hydrostatic Transmission Filter:
KOHLER AIR AND OIL FILTER PART NUMBERS:
Refer to engine manufacturer’s manual for recom-
mendations regarding frequency of service required
for engine oil changes and air filter maintenance.
Protect your engine investment, use only original
equipment filters.
MODEL ZTR 7525 (25HP):
Air Filter & Pre-Cleaner Kit
Engine Oil Filter
78002
78006
IMPORTANT:
Some applications, extreme dirt conditions, or the use
of a grass catcher may require that the engine used on
the Model ZTR 7525 be fitted with an optional Kohler
fresh air filter system. Check with your engine service
center for availability.
38
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:
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39
ZTR®Mowers
The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects or other
reproductive harm.
WARNING:
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
7500 Series
Model 7525
Part No. 13636-0702
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