Model 2560 ZTR® Model Year 2004
IMPORTANT - READ CAREFULLY The Dixon ® ZTR® Mower is both easy and fun to operate. However, any power mower must be operated properly to be safe. It is not a toy or a recreational vehicle. Before you start to use the mower, read the operator’s manual carefully and become completely familiar with the controls. The information contained in this manual applies to all Dixon® ZTR® Model 2560 Mowers. Your Dixon dealer will gladly answer any questions. See your dealer for warranty service, parts and repairs.
INDEX Page Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . .15 Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19 Operation Instructions. . . . . . . . . . . . . . . . . . . 20-28 Care & Maintenance. . . . . . . . . . . . . . . . . . . . . .
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.
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.
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.
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.
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.
SAFETY DO (CONTINUED) •Avoid starting or stopping on a slope. If tires lose traction, disengage the blades and proceed slowly down the slope. •If front wheels lift off the ground, pull the levers back to stabilize the mower. DO NOT •Do not turn on slopes unless necessary, and then, turn slowly and gradually downhill, if possible. •Do not mow near drop-offs, ditches or embankments. The mower could suddenly turn over if a wheel is over the edge of a cliff or ditch, or if an edge caves in.
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.
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.
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.
DIXON LIMITED WARRANTY POLICY Pro Models 1950 ~ 2300 ~ 2560 DIXON ZTR MOWERS ARE WARRANTED AGAINST DEFECTS IN MATERIALS AND WORKMANSHIP AND PROVIDES FOR REPLACEMENT OR REPAIR OF PARTS INCLUDING LABOR COSTS. THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS AND LIMITATIONS. 1. Home Owner Application: Dixon Model 2560 used only at owner’s primary place of residence is warranted for a period of two (2) years from date of purchase. Frame, body panels and fenders are warranted for the life of the mower. 2.
SPECIFICATIONS Model 2560 CHASSIS: Folded sheet metal and rectangular tube BODY: Folded sheet metal SEAT: Designed for operator comfort with suspension system and padded back and arm rests. Seat is adjustable fore and aft. MOWER DECK: Deck is made of 10 GA fabricated welded construction with 7 GA reinforcement plates. Three blades combine for a 60" cut width. Cut height approximately 1.5" to 5" via 10 position lift handle.
SEAT ADJUSTMENT INSTRUCTIONS Model 2560 1. Grasp seat slide adjuster and move it into adjustment position. 2. Slide seat forward or backward. 3. Release seat slide adjuster.
CONTROLS 16
CONTROLS CONTROL LEVERS Note: For access to the seat, move control levers to neutral position and swing them outward. TO GO FORWARD: •From neutral position, gently push both control levers forward. •To increase speed, move levers further forward. TO GO BACKWARD: •From neutral position, gently pull both control levers toward you. TURNING: •Turning is controlled by moving one control lever slightly forward or rearward of the other. •To turn left, move left lever rearward of the right lever.
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.
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.
OPERATION INSTRUCTIONS The safe and successful operation of the ZTR Model 2560 will depend upon the operator having the correct knowledge of all controls used on the mower and making good judgements about the terrain to be mowed. NEVER allow anyone to operate the mower without complete knowledge of all controls and their functions. During initial operation, “learning to drive”, set throttle at slow speed. Sound judgement by the owner will prevent accidents.
OPERATION INSTRUCTIONS BEFORE OPERATING MOWER: 1. Read and observe all safety instructions on your mower and in the manual. 2. Read engine manufacturer’s operating and maintenance instructions. 3. Discuss proper maintenance with your dealer. 4. Check engine oil. 5. Check fuel cap to be sure it is in place. 6. Be sure parking brake is on. 7. Mower blade drive is off. 8. Know how to stop engine (turn key to off position).
OPERATION INSTRUCTIONS TESTING OF SAFETY INTERLOCK SYSTEMS: Do not operate mower if safety switches are not operating properly. Your Zero Turning Radius Mower is equipped with control interlocks for your safety. 1. The mower blades must be disengaged before the engine will start. 2. The brake lever must be engaged (upward position) before engine will start. 3. The engine will stop if the mower blade clutch is engaged when the operator leaves the driver's seat. 4.
OPERATION INSTRUCTIONS BLADE DRIVE SWITCH TEST (ELECTRIC CLUTCH): 1. With the electric blade drive switch turned on and the parking brake in “ON” position, engine should not turn over or attempt to start when key switch is moved to the start position. 2. In a safe area, away from bystanders, start the engine, place throttle setting at maximum or full. Engage the blade drive through the electric clutch switch. Raise weight slightly off of seat. ENGINE SHOULD STOP. 3.
OPERATION INSTRUCTIONS STARTING INSTRUCTIONS (cold engine): 1. Pull choke control lever up. 2. Push throttle control lever to 1/2 setting. 3. Insert ignition key and turn to “START” position. When engine starts, release ignition key. Key will return to “RUN” position. 4. Once engine starts to warm up, slowly push choke control down to fully open position. 5. Move throttle control lever to the wide open or maximum setting for actual operation of the mower deck. 6.
OPERATION INSTRUCTIONS STARTING INSTRUCTIONS (engine has been operated): 1. Move throttle control lever to 1/4 to 1/2 setting. 2. Insert ignition key and turn to “START” position. When engine starts, release ignition key. Key will return to “RUN” position. 3. Move throttle control lever to the wide open or maximum setting for actual operation of the mower deck. Note: Model ZTR 2560 may require a partial choke setting to start even if the engine has been operated for a period of time. 4.
OPERATION INSTRUCTIONS In order to achieve optimum cutting performance, please read and follow the tips listed below. Additional information can be found in the Troubleshooting Guide on Page 40-41. CAUTION Be sure that deflector is properly installed on the discharge chute. 1. Set engine speed control to the wide open or full setting. 2. Do Not Attempt To Cut Grass When It Is Wet. Wet grass will clog the underside of the deck and discharge area. 3.
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%.
OPERATION INSTRUCTIONS TO FREE WHEEL MACHINE (UNLOCK TRANSMISSION): Always turn off engine before engaging or disengaging the hydro release (free wheel) valves. Never attempt to move the valves with the engine running. The hydro release valves are located beneath the seat, between the fuel tank and hydro pumps. To access release valves, tilt seat plate forward. Use a 5/8” wrench to rotate bolt counter-clockwise two full turns to disengage pump. Repeat procedure for opposite pump.
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.........
CARE AND MAINTENANCE ENGINE: For complete maintenance and operating information of the engine, please refer to the maintenance instructions furnished by the engine manufacturer and included in your Zero Turn Radius mower information packet. Note: Air intake screen must be kept clean. If plugged, engine may be seriously damaged by overheating. BATTERY: CAUTION Battery contains sulfuric acid electrolyte which is poisonous and corrosive.
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.
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.
CARE AND MAINTENANCE ELECTRICAL SYSTEMS: Keep all connections clean and tight. CLEANING THE MOWER: Wash mower periodically. Clean above and below the deck. High pressure washing and alkaline based soaps can cause damage to bearings and other parts of the mower. After washing your mower, start the engine and engage the mower deck for a few minutes to disperse any water that may have accumulated in bearings, pulleys or fans. Note: Allow mower to cool before washing.
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.
CARE AND MAINTENANCE PROCEDURE FOR RAISING AND LOWERING THE DECK FOR SERVICING: A . Move cut height adjustment lever to lowest position. B. Flip up the foot deck to allow access to the engine to deck drive belt. Roll the engine to deck drive belt off the center spindle. C . Lift the rear corner of the deck and remove 1/2” x 1-1/2” clevis pin from lift link/eye bolt. Repeat for the other side. D .
MOWER SHOWN IN OPERATIO N POSITION CARE AND MAINTENANCE 36
MOWER SHOWN IN SERVICING POSITION CARE AND MAINTENANCE 37
CARE AND MAINTENANCE LEVELING THE DECK: 1. Set the tire pressure on all 4 tires. 2. Front casters must be rotated in the direction of forward travel. 3. Move the tractor to a hard level surface. 4. Put the mower deck in the number 3 deck height position. 5. Rotate the 2 outer spindles so the blades point outboard. 6. Adjust front hangers to level deck side to side, by measuring at blade tips. 7. Rotate all 3 spindles until the blades are fore and aft. 8.
STANDARD SERVICE PARTS LIST MODEL ZTR 2560: Blades 60” Hi-Lift (Standard)-P/N 12421 Low-lift-P/N 12451 Gator-P/N 12508 Belts Engine to Mower Deck Belt-P/N 1300 Serpentine Belt 60”-P/N 9758 Engine to Hydro Belt-P/N 61778 Hydrostatic Transmission Filter-P/N 7252 KOHLER AIR AND OIL FILTER: Refer to engine manufacturer’s manual for recommendations regarding frequency of service required for engine oil changes and air filter maintenance. Protect your engine investment, use only original equipment filters.
TROUBLESHOOTING 1.
TROUBLESHOOTING 6.
NOTES 42
OWNER INFORMATION DIXON INDUSTRIES, INC. a BLOUNT International Inc. Co. P.O.
ZTR®Mowers WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Dixon® and ZTR® are registered trademarks of Dixon Industries, Inc. DIXON INDUSTRIES, INC. a BLOUNT International Inc. Co. P.O. Box 1569 Coffeyville, Ks 67337-0945 620-251-2000 Model 2560 Part No.
