Dixon ZTR 3500 Series, Operator'S Manual

Page 1: ...8000D SERIES 2003 OPERATOR S MANUAL All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 2: ...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 All manuals and user guides at all guides com ...

Page 3: ...y 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 All manuals and user guides at all guides com ...

Page 4: ...D CAN CAUSE SERIOUS INJURY OR DEATH The most common causes of injury to the operator or bystander read and understand this manual to prevent injuries BLADE CONTACT TIP OVER RUN OVER BACK OVER SAFETY All manuals and user guides at all guides com ...

Page 5: ...ighted 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 Follow recommended safety precautions and safe operating practices SAFETY All manuals and ...

Page 6: ...re 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 turnin...

Page 7: ...afety 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 Maintai...

Page 8: ...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 a...

Page 9: ...wing 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...

Page 10: ...aused 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...

Page 11: ...irs 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 s...

Page 12: ...on 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 An...

Page 13: ... water cooled diesel horizontal shaft pressure feed lubrication with spin on oil filter fuel filter with primer pump and water separator paper element with cyclone pre cleaner STARTING Electric by key switch operation with safety interlocks on parking SYSTEM brake blade drive clutch and control levers TIRES Front 13 6 5x6 Rear 23 10 5x12 RECOMMENDED Front 16 20 lbs TIRE PRESSURE Rear 8 14 lbs CAPA...

Page 14: ...urning 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 tra...

Page 15: ...fore 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 Grasp lever with right hand 2 Depress thumb lever to release Move to desired position 3 Release lever to lock into position Select cut height insert pin into first hole below the lift lever Ten h...

Page 16: ...osing 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 th...

Page 17: ...ntrols 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 ...

Page 18: ...18 CONTROLS All manuals and user guides at all guides com ...

Page 19: ...te 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 ...

Page 20: ...fety 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 All manuals and user guides at all gu...

Page 21: ...FE 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 ...

Page 22: ...tion 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 Do not operate the engine in an enclosed area due to the harmful exhaust gas produced STOPPING INSTRUCTIONS 1 Turn mower bl...

Page 23: ...charge chute 1 Start engine and set throttle at full speed 2 Set desired cut height 3 Release park brake 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 CAUTION CAUTION All manuals and user guides at all guides com ...

Page 24: ...e 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...

Page 25: ... 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 ...

Page 26: ...e seat see instructions on Page 25 rotate the transmission hex valve located on the top of each transmission approxi mately one turn counter clockwise To re engage the transmission rotate each transmis sion hex valve clockwise to the end of its travel Return the seat to the operating position Note Before pushing or towing the tractor the trans mission must be unlocked and the parking brake release...

Page 27: ... common safety practices with tools ve all common safety practices with tools ve all common safety practices with tools 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 be...

Page 28: ...ecked 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...

Page 29: ...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 CARE AND MAINTENANCE BELTS Check belts every 50 hours Replace any belts found to be in poor condition Stop engine and remove ignition key for safety Wear heavy thick gloves whe...

Page 30: ...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 All manuals and user guides at all guides com ...

Page 31: ...ow 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 moto...

Page 32: ...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 PARKING BRAKE ADJUSTMENT All manuals and user guides at all guides com ...

Page 33: ...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 CARE AND MAINTENANCE All manuals and user guides at all guides com ...

Page 34: ...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 Raise seat 2 Drain radiator 3 Remove radiator mounting hardware and hoses 4 Remove radiator 5 Remove double u joint flange bolts and remove double u joint 6 Rotate the spring loaded take up idler toward the le...

Page 35: ... 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 All manuals and user guides at all guides com ...

Page 36: ...are not turning 7 Repeat steps 3 6 for the other side 8 Shut off engine before removing the blocks 9 Return the seat to the operating position To adjust neutral springs 1 Loosen set screws of front and rear spring stop collars located on the control rods requires a 1 8 Allen wrench 2 Move control handle full forward 3 Move front spring stop collar rearward until it compresses spring approximately ...

Page 37: ...2 Move the levers inboard to the operating position 3 Loosen the set screw of the clamp collars which lock the upper arms to the lower arms 4 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 5 Rotate the arms until they have the desired orientation front to back 6 Tighten the clam...

Page 38: ...ut off the engine 3 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 s...

Page 39: ...mber 3 deck height position 5 Loosen the jam nuts on the front and rear deck hangers 6 Rotate the 2 outer spindles so the blades point outboard 7 Adjust front hangers to level deck side to side 8 Rotate all 3 spindles until the blades are fore and aft 9 Adjust rear hangers until deck is level to 1 8 higher in the rear 10 Retighten the jam nuts on the front and rear deck hangers All manuals and use...

Page 40: ...el 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 c...

Page 41: ...n 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 Oper...

Page 42: ...recommen dations 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 13480 Engine Oil Filter 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 optiona...

Page 43: ...__ ___________________ ___________________ ___________________ ___________________ ___________________ ___________________ ___________________ ___________________ ___________________ ___________________ ___________________ ___________________ ___________________ ___________________ ___________________ ___________________ ___________________ ___________________ ___________________ _________________...

Page 44: ...rnational Inc Co P O Box 1569 Coffeyville Ks 67337 0945 620 251 2000 8000 Series Diesel Model 8026D Part No 13638 xxxx W W W W WARNING ARNING ARNING ARNING ARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm All manuals and user guides at all guides com ...