OPERATOR’S MANUAL 6000 SERIES FORWARD MOUNT ZTR® 2002
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® 6000 Series Commercial Mowers. Your Dixon dealer will gladly answer any questions.
INDEX Page Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . . . . . . . .14 Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-17 Operation Instructions. . . . . . . . . . . . . . . . . . . 18-24 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 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 6000 & 7000 Series WARRANTY: Home Owner Application: This Dixon Warranty term is for a period of two (2) 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 400 hours whichever comes first.
SPECIFICATIONS 6000 Series Forward Mount CHASSIS: Sheet metal construction frame. BODY: Folded sheet metal. Seat lifts up for access to battery and belt service. SEAT: Designed for operator comfort by use of high density closed cell foam padded back and arm rests, upholstered with CorduraTM waterrepellent fabric. Seat is adjustable fore and aft. MOWER DECK: Two decks are available. Both are made of 12 GA fabricated welded construction with 10 GA reinforcement plate.
SEAT ADJUSTMENT INSTRUCTIONS 6000 SERIES 14 1. Grasp seat slide adjuster and move it into adjustment position. 2. Slide seat forward or backward. 3. Release seat slide adjuster.
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 The parking brake is designed to hold the mower from moving and is not intended for use in stopping the mower while it is in motion. Engage parking brake CAUTION before starting engine. TO SET PARKING BRAKE The hand operated parking brake is located at the right hand side of the mower. To engage brake, pull rearward. To release brake, move lever forward. NOTE: Always set parking brake before dismounting. Release parking brake before moving mower.
CONTROLS MOWER BLADE SWITCH: Located on the control panel to the operator’s right. To engage blades: pull up on switch To disengage blades: push down CHOKE CONTROL LEVER: Located on control panel to operator’s left. Use to start a cold engine. THROTTLE CONTROL LEVER: Located on control panel to operator’s right. Controls engine speed, slow to maximum.
OPERATION INSTRUCTIONS The safe and successful operation of the 6000 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 initial operation, “learning to drive”, set throttle at slow speed. Sound judgement by the operator will prevent accidents.
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 (cold engine): 1. Operator must be seated in normal operating position. 2. Set parking brake. 3. Push choke control lever fully foward. 4. Push throttle control lever to 1/2 setting. 5. Insert ignition key and turn to “start” position. When engine starts, release ignition key. Key will return to “run” position. 6. Once engine starts to warm up, slowly move choke control lever to the fully closed position. 7.
OPERATION INSTRUCTIONS STARTING INSTRUCTIONS (engine has been operated): 1. Operator must be seated in normal operating position. 2. Set parking brake. 3. Push throttle control lever to 1/4 to 1/2 setting. 5. Insert ignition key and turn to “start” position. When engine starts, release ignition key. Key will return to “run” position. 6. Move throttle control lever to the wide open or maximum setting for actual operation of the mower deck.
OPERATION INSTRUCTIONS MOWING INSTRUCTIONS: CAUTION 1. 2. 3. 4. Start engine and set throttle at full speed. Set desired cut height. Release park brake. Move control levers in and operate per the control instructions on Page 15. CAUTION 5. 22 Be sure that deflector is properly installed on the discharge chute. Check the area to assure there is no one near. Engage mower blades.
OPERATION INSTRUCTIONS To Free Wheel Machine (unlock transmission for towing): The free wheel levers are located on each side of the mower below the seat mount (flip up the foot deck to access them). Lift the levers slightly, push them to the rear and down to release the transmissions for free wheeling. To engage the transmissions, lift the levers slightly, pull them forward and then down. BEFORE PUSHING OR TOWING TRACTOR, TRANSMISSION MUST BE UNLOCKED, AND PARKING BRAKE RELEASED.
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.
CARE AND MAINTENANCE CAUTION Before performing any maintenance, turn off engine, allow to cool & remove key. 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 and cooling fans. . . . . . . .before each use Check air intake screen. . . . . . .
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: Battery contains sulfuric acid electrolyte which is CAUTION 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 BELTS: The main hydro drive belt should be checked after the first 10 hours and every 50 hours thereafter. Replace any belts found to be in poor condition. The deck belt is equipped with a spring loaded belt tightener and does not require tightening adjustments. The hydrostatic transmission belt is adjusted manually (see page 32 for tensioning instructions). LUBRICATION: A. B. C. D. E. F. Engine: Follow engine manufacturer’s recommendation.
CARE AND MAINTENANCE HYDROSTATIC TRANSMISSION: Before each use, check to be sure that the cooling fins of the hydrostatic transmission are clean. Excessive accumulation of oil, dirt, or trash may cause the transmission to overheat. NEVER WASH ACROSS TOP OF RESERVOIR with water or steam. Fill reservoir as required per instructions below. CHECKING & REPLENISHING OIL IN HYDROSTATIC TRANSMISSION: Check the oil level in hydrostatic transmission oil reservoir after every 25 hours of usage.
CARE AND MAINTENANCE PARKING BRAKE ADJUSTMENT With the brake handle in the release position, remove the cotter pin from the castle nut. Insert a 0.010 feeler gauge between the brake disc and the brake puck. Tighten the castle nut with the feeler gauge inserted until the gauge fits snugly between the disc and puck. The gap should not be so tight that the feeler gauge cannot be reinserted after removal. Back the castle nut to the closest pin hole and reinsert the cotter pin. Repeat for other side.
CARE AND MAINTENANCE CHECK DECK DRIVE GEARBOX FLUID LEVEL: The fluid level only needs to be checked if oily residue is found on the gearbox housing. 1. Rotate deck into upright position (see deck servicing procedure). 2. Remove the hex head plug at the low end of the gearbox housing. (Plug closest to the drive shaft.) The fluid level should be level with the bottom of the threaded hole. CHANGING THE FLUID IN DECK DRIVE GEARBOX: 1.
CARE AND MAINTENANCE HYDROSTAT DRIVE BELT TENSION ADJUSTMENT: In normal use the hydrostat drive belt tension should be checked after the first 20 hours of use for normal wear and stretch. It may be adjusted as follows: 1. 2. Loosen the idler pulley locking nut until the idler pulley can be just moved relative to the mounting bracket. Tighten the tension adjust bolt until the belt is tight enough to prevent belt slippage. Belt should deflect approximately 3/8” to 5/8” under moderate pressure.
CARE AND MAINTENANCE STEERING CONTROL ADJUSTMENTS: To adjust neutral: 1. 2. 3. 4. Remove fender skirts from each side of the machine. Block up the unit so drive wheels are off ground. Start engine and run at fast idle with steering control levers in “out” position. Brake must be disengaged and seat switch activated. Loosen the locknuts tightened against the rod end ball joints in the upper linkage assembly. Note: One of these is a left hand nut and will have to be turned backwards. 5. 6. 7. 8.
CARE AND MAINTENANCE STEERING CONTROL ADJUSTMENTS (continued): To adjust “IN” position of the steering controls: 1. 2. 3. 4. 5. Remove the two front bolts, lockwashers, and washers which hold the fender cap. Pull the boot from the hole in the fender cap, exposing the cast iron lever. Using a 5/32” Allen wrench, turn the setscrew to adjust the stop. Replace the boot into the hole in the fender cap. Replace the two front bolts, lockwashers and washers.
CARE AND MAINTENANCE STEERING CONTROL ADJUSTMENTS (continued): Adjusting for Straight Forward Tracking: In large open area, actuate the control handles into the full forward position. If mower veers in either direction (left or right) some adjustment is necessary. 1. If mower veers to right, right hydrostat needs to be sped up. If mower veers to left, left hydrostat needs to be sped up. Stop machine and shut off engine. Slightly loosen bolt at lower end of upper linkage assembly on side that is slower.
CARE AND MAINTENANCE TILTING THE DECK (see diagram-page37) 1. 2. 3. 4. 5. 6. 7. Set the parking brake. Raise the foot deck into vertical position and lock into place. Remove the quick release pin from the anti-buck cylinder at deck end. Lift the cylinder straight up. Use left-hand control lever to hold cylinder in up-right position. Place the deck lift handle in the lowest cutting position. Use lift assist bar, located on left-hand side of deck, inside the deck lift tube.
CARE AND MAINTENANCE DOWN HANGER IN ENGAGED POSITION FOOT DECK IN VERTICAL POSITION FOOT DECK LOCKING DEVICE USE THIS HANDLE TO HELP DISENGAGE DOWN HANGER ANTI-BUCK CYLINDER QUICK RELEASE PIN (deck lift handle) QUICK RELEASE PIN (anti-buck cylinder) LIFT CORNER OF DECK MIDDLE HOLE ON ANTI-BUCK CYLINDER HOLDER DECK LIFT HANDLE CATCH DECK LIFT BAR DECK LIFT TUBE (Lift Assist Bar Inside) 37
CARE AND MAINTENANCE LEVELING THE DECK: The deck comes from the manufacturer pre-leveled. If the deck does appear to be cutting unlevel follow this procedure. 1. Set tire pressure on all of the tires to correct specifications (see page 26). 2. Place machine on a level slab of concrete. 3. Move blades by hand so all the blades are pointed in the same direction (see diagram on page 39). Measure from the blade tip (beveled edge) to the ground, all three blades.
CARE AND MAINTENANCE BLADE DISCHARGE SIDE DECK SPINDLE BELT DIAGRAM (TOP VIEW) 39
TROUBLESHOOTING 1.
TROUBLESHOOTING 7. ENGINE SOMETIMES SKIPS AT HIGHER SPEED Incorrect ignition timing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer Carburetor maladjusted- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -readjust carburetor Faulty spark plugs- - - - - - - - - - - - - - check spark plug or condition and reset gap* Bouncing off seat safety switch- - - - - - - - - - - - - - - - - - - -slow down on rough terrain 8.
STANDARD SERVICE PARTS LIST MODEL ZTR 6023: Blades: Blades: Lo-Lift P/N 60293 (standard) Hi-Lift P/N 60295 Serpentine Belt: Engine to Hydros: Clutch to Driveshaft: P/N P/N P/N P/N Hydrostatic Transmission Filter: P/N 7252 60194 (48”) 61086 (60”) 61101 60187 KOHLER 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 6000 Series Model 6023 Part No.
