Dixon ZTR 2560 User manual

Model Year 2004Model Year 2004
Model Year 2004Model Year 2004
Model Year 2004
ZTR®
Model 2560Model 2560
Model 2560Model 2560
Model 2560

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.

3
INDEX
Page
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . .15
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19
Operation Instructions. . . . . . . . . . . . . . . . . . . 20-28
Care & Maintenance. . . . . . . . . . . . . . . . . . . . . .29-38
Standard Service Parts List. . . . . . . . . . . . . . . . . . . .39
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . .40-41
Model2560
PartNo.61935-0603

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

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
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

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, toys, wire,
etc., which could be picked up and thrown by the
blade.
•Be sure the area is clear of other people before mow-
ing. 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.
SAFETY

7
GENERAL OPERATION (continued) :
•Turn off blades when not mowing.
•Stop engine before removing grass catcher or unclog-
ging 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 withside
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.
WARNING:
The engine exhaust from this product contains chemicals known to the
State of California to cause cancer, birth defects or other reproductive
harm.
SAFETY

8
SLOPE OPERATION:
Slopesareamajorfactorrelated to loss-of-controlandtip-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 attach-
ments. 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.
SAFETY

9
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.
• 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.
SAFETY

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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 seri-
ously 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.

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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 contain-
ers 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 com-
plete. Do not use a nozzle lock-open device.
SAFETY

12
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.
SAFETY

13
DIXONLIMITEDWARRANTYPOLICY
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. HomeOwnerApplication: DixonModel2560usedonlyatowner’sprimaryplaceofresidence
iswarrantedforaperiodoftwo(2)yearsfromdateofpurchase. Frame,bodypanelsand
fendersarewarrantedforthelifeofthemower.
2. CommercialApplication: Definedasuseotherthan,orinadditionto,mowingatowner’s
primaryplaceofresidence.Unitsusedincommercialapplicationarewarrantedforaperiodof
one(1)yearfromdateofpurchaseor400hoursofuse,whichevercomesfirst.
3. Warrantyappliesonlytooriginalretailpurchaserofnewandunusedmowersandaccessories.
4. AllDixonwarrantymustbeaccomplishedbyauthorizedDixondealersandinaccordancewith
Dixonwarrantypolicyandallowances. AllwarrantyclaimsmustbeapprovedbyDixon
Industries,Inc.
5. BatteryWarranty: limitedto90daysfromdateofpurchase.
6. AccessoriesWarranty(grasscatchers,snowblades,covers,etc.):Limitedto90daysfrom
dateofpurchase.
7. Warrantydoesnotapplytodamageintransitorincidentsofmisuse,negligence,accidents,or
alteration. TheuseofpartsorcomponentsotherthanthosesuppliedbyDixonIndustries
VOIDSALLWARRANTY.
8. Thefollowingitemsarenotcoveredbythiswarrantypolicy:
(a) Pickupanddeliverychargesfortransportationofmowertoandfromanauthorized
Dixondealer’splaceofbusiness.
(b) Routinemaintenanceoradjustments.
(c) Belts/blades/hydrofilters.
(d) Engines-AllenginesusedonDixonZTRmowersarewarrantedbyeachindividual
enginemanufacturer.
(e) Anycostsorexpenseofprovidingsubstituteequipmentwhilerepairworkisbeing
performedonawarrantedmower.
9. Thereisnootherexpresswarranty. Impliedwarranties,includingthoseofmerchantabilityand
fitnessforaparticularpurposearelimitedtothesamedurationoftheexpresswarrantyandto
theextentpermittedbylawanyandallimpliedwarrantiesareexcluded.Liabilitiesfor
consequentialdamagesunderanyandallwarrantiesareexcluded.

14
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.
BLADEDRIVE: Electricclutch
DRIVE SYSTEM: Each rear wheel is independently driven by a HydroGear BDP
10A pump and a White CE 14 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 Electric by key switch operation with safety interlocks on
SYSTEM: parking brake and blade drive clutch.
TIRES: Front13-5.00x6
Rear23-9.50x12
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 916lbs.
Additional information provided in service instructions under the individual
component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

15
SEAT ADJUSTMENT INSTRUCTIONS
Model 2560
1. Grasp seat slide adjuster and move it into
adjustmentposition.
2. Slide seat forward or backward.
3. Release seat slide adjuster.
Seat Slide Adjuster

16
CONTROLS

17
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.
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.

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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.
•Whilemoving,throttlecontrol shouldbesetto MAXIMUMorwide
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.
HYDRAULIC DRIVE SYSTEM:
Allowsthe mowerto turnon itsownaxis (zeroturning radius).
Each lever controls one side of the mower.
NOTE: The pressure required to operate the mower is very light.

19
CONTROLS
BLADE DRIVE:
Locatedoncontrolpanel,onoperator'sright.
To engage blades: Pull up on the switch.
To disengage blades: Push down.
MOWER DECK CUT HEIGHT LIFT LEVER:
Locatedto the right and front ofthe
operator.
Controlsthe cuttingheight.
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
fortransport.

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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 with-
out 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 acci-
dents.