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Dixon ZTR 7523 manual

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Table of contents for the manual

  • Page 1

    ZTR ® OPERA T OR’S MANUAL 7500 SERIES 2002[...]

  • Page 2

    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 [...]

  • Page 3

    3 INDEX Page Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 2 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . .14 Controls. . . . . . . [...]

  • Page 4

    4 RIDING LAWN MOWERS, IF IMPROPERLY OPERATED, 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[...]

  • Page 5

    5 Safety Alert Symbol When you see this symbol, BE ALERT to the potential for injury. 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 serio[...]

  • Page 6

    6 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[...]

  • Page 7

    7 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 loa[...]

  • Page 8

    8 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 ro[...]

  • Page 9

    9 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 adu[...]

  • Page 10

    10 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[...]

  • Page 11

    11 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 u[...]

  • Page 12

    12 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 6000, 7000 & 7500 Series WARRANTY: Home Owner Application: This Dixon Warranty term is for a period of two (2) years from date of purchase. Commercial Applic[...]

  • Page 13

    13 SPECIFICATIONS 7500 Series CHASSIS: Folded sheet metal and rectangular tube BODY: Folded sheet metal SEAT: Designed for operator comfort with padded back and arm rests. Seat is adjustable fore and aft. MOWER DECK: Two decks are available. Both decks are made of 10 GA fabricated welded construction with 7 GA reinforcement plate. Three blades comb[...]

  • Page 14

    14 SEAT ADJUSTMENT INSTRUCTIONS Model 7523 1. Grasp seat slide adjuster and move it into adjustment position. 2. Slide seat forward or backward. 3. Release seat slide adjuster. Seat Slide Adjuster[...]

  • Page 15

    15 Blade Clutch Switch Choke Steering Control Levers Parking Brake Lever Cut Height Stop Pin Cut Height Adjustment Lever Throttle Ignition Key CONTROLS 7523[...]

  • Page 16

    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[...]

  • Page 17

    17 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 th[...]

  • Page 18

    18 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. Seven positions of adjustment. Lift lever and place stop in hole corresonding to the desi[...]

  • Page 19

    19 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 initi[...]

  • Page 20

    20 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[...]

  • Page 21

    21 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 bystandards, start the engine, place throttle setting at maxi[...]

  • Page 22

    22 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 lever down[...]

  • Page 23

    23 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 oper[...]

  • Page 24

    24 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. Set engine speed control to the wide open or full setting. 2. Do Not [...]

  • Page 25

    25 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. Mainta[...]

  • Page 26

    26 OPERATION INSTRUCTIONS TO FREE WHEEL MACHINE (UNLOCK TRANSMISSION FOR TOWING): The transmission release valve is 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 fo[...]

  • Page 27

    27 CARE AND MAINTENANCE CAUTION CAUTION CAUTION CAUTION CAUTION Bef Bef Bef Bef Bef ore perf ore perf ore perf ore perf ore perf or or or or or ming an ming an ming an ming an ming an y maintenance y maintenance y maintenance y maintenance y maintenance , tur , tur , tur , tur , tur n off engine n off engine n off engine n off engine n off engine ,[...]

  • Page 28

    28 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. BA[...]

  • Page 29

    29 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 protectio[...]

  • Page 30

    30 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 cau[...]

  • Page 31

    31 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.[...]

  • Page 32

    32 A. Remove cut height adjustment pin and completely lower the cut height adjustment lever. Re-insert the cut height adjustment pin into the 3- 1/2 ” cut height position (this will lock the cut height adjustment lever into the lowest position). B. Flip up the foot deck to allow access to the engine to deck drive belt. Roll the engine to deck dri[...]

  • Page 33

    33 CARE AND MAINTENANCE LEVELING THE DECK: A. Set the tire pressure on all four tires. B. 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-scal[...]

  • Page 34

    34 CARE AND MAINTENANCE Center Deck Spindle Deck Lift Bolt Cut Height Adjustment Lever Locking Pin Deck Front Caster Wheels positioned out of the way Rear Deck Mounting Latch Cut Height Adjustment Pin 7523 MOWER SHOWN IN OPERA TION POSITION Rear Corner[...]

  • Page 35

    35 CARE AND MAINTENANCE Engine to Deck Drive Belt Hoist Deck Latch in locked position Foot Deck in up position 7523 7523 MOWER SHOWN IN SER VICING POSITION[...]

  • Page 36

    36 1 . ENGINE WON’T TURN OVER Mower blades engaged- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -disengage blades Blown fuse- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -replace fuse Dead battery- - - - - - - - - - - [...]

  • Page 37

    37 TROUBLESHOOTING 6 . 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- - - - - - - - - - - - - - - - - [...]

  • Page 38

    38 STANDARD SERVICE PARTS LIST MODEL ZTR 7523: Blades 52” Hi-Lift: P/N 60532 Blades 60” Hi-Lift: P/N 60295 Blades 60” Lo-Lift: P/N 60293 Engine to Mower Deck Belt: P/N 61515 Serpentine Belt 52”: P/N 61511 Serpentine Belt 60”: P/N 61512 Engine to Hydro Belt: P/N 61778 Hydrostatic Transmission Filter: P/N 7252 KOHLER AIR AND OIL FILTER PART[...]

  • Page 39

    39 OWNER INFORMATION Date Purchased _ ________________________________ Mower Model Number ____________________________ Mower Serial Number ____________________________ Purchased From ___ _____________________________ Name ________________________________ Address ________________________________ DATE OIL CHANGED: DATE ENGINE TUNED: _________________[...]

  • Page 40

    ZTR®Mowers ZTR®Mowers ZTR®Mowers ZTR®Mowers ZTR®Mowers 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 7523 Part No. 61783-0102 W W W W W ARNING: ARNING: ARNING: ARNING: ARNING: The engine exhaust[...]