8000D SERIES OPERATORS 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 operators 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.
INDEX Page Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-18 Operation Instructions. . . . . . . . . . . . . . . . . . . 19-26 Care & Maintenance. . . . . . . . . . . . . . . . . . . . . .27-39 Troubleshooting. . . . . . . . . . . . .
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 crossingroadways. 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 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 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.
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.
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.
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 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.
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.
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 operators right. Controls engine speed.
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.
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 drivers seat. 4.
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.
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.
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.
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.
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.
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.
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......................................
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.
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: 30 1. Engine: Follow engine manufacturers 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.
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.
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.
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.
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.
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.
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.
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.
TROUBLESHOOTING 1.
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.
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.
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 8000 Series (Diesel) Model 8026D Part No.
