Dixon ZTR 6023 manual

ZTR ® OPERA T OR’S MANUAL 6000 SERIES FORWARD MOUNT 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 [...]

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

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 serio[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 buildup. Clean up[...]

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 Series WARRANTY: Home Owner Application: This Dixon Warranty term is for a period of two (2) years from date of purchase. Commercial Application:[...]

13 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 water- repellent fabric. Seat is adjustable fore and af[...]

14 SEAT ADJUSTMENT INSTRUCTIONS 6000 SERIES 1 . Grasp seat slide adjuster and move it into adjustment position. 2 . Slide seat forward or backward. 3 . Release seat slide adjuster.[...]

15 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[...]

16 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 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 br[...]

17 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[...]

18 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 o[...]

19 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 e[...]

20 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 [...]

21 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. [...]

22 OPERATION INSTRUCTIONS MOWING INSTRUCTIONS: CAUTION Be sure that deflector is properly installed on the discharge chute. 1 . Start engine and set throttle at full speed. 2 . Set desired cut height. 3 . Release park brake. 4 . Move control levers in and operate per the control instructions on Page 15. CAUTION Check the area to assure there is no [...]

23 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 leve[...]

24 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 m[...]

25 CARE AND MAINTENANCE CAUTION CAUTION CAUTION CAUTION 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 [...]

26 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[...]

27 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[...]

28 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 pag[...]

29 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[...]

30 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 aft[...]

31 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 l[...]

32 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. Loosen the idler pulley locking nut until the idler pulley can be just moved relative to the mounting bracket. 2. Tighten the[...]

33 STEERING CONTROL ADJUSTMENTS: To adjust neutral: 1. Remove fender skirts from each side of the machine. 2. Block up the unit so drive wheels are off ground. 3. Start engine and run at fast idle with steering control levers in “out” position. Brake must be disengaged and seat switch activated. 4. Loosen the locknuts tightened against the rod [...]

34 CARE AND MAINTENANCE STEERING CONTROL ADJUSTMENTS (continued): To adjust “IN” position of the steering controls: 1. Remove the two front bolts, lockwashers, and washers which hold the fender cap. 2. Pull the boot from the hole in the fender cap, exposing the cast iron lever. 3. Using a 5/32” Allen wrench, turn the setscrew to adjust the st[...]

35 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[...]

36 CARE AND MAINTENANCE TILTING THE DECK (see diagram-page37) 1. Set the parking brake. 2. Raise the foot deck into vertical position and lock into place. 3. 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. 4. Place the deck lift h[...]

37 CARE AND MAINTENANCE FOOT DECK LOCKING DEVICE MIDDLE HOLE ON ANTI-BUCK CYLINDER HOLDER DECK LIFT BAR DECK LIFT HANDLE CATCH QUICK RELEASE PIN (deck lift handle) ANTI-BUCK CYLINDER DECK LIFT TUBE (Lift Assist Bar Inside) QUICK RELEASE PIN (anti-buck cylinder) LIFT CORNER OF DECK DOWN HANGER IN ENGAGED POSITION FOOT DECK IN VERTICAL POSITION USE T[...]

38 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 [...]

39 BLADE DISCHARGE SIDE DECK SPINDLE BELT DIAGRAM (TOP VIEW) CARE AND MAINTENANCE[...]

40 1 . ENGINE WON’T TURN OVER Mower blades engaged- - - - - - - - - - - - - - - - - - - - - - -disengage blades Drive not in neutral - - - - - - - - - - - - - - - - - - move control levers to neutral “OUT” Breaker trips- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - reset breake r Dead bat[...]

41 TROUBLESHOOTING 7 . ENGINE SOMETIMES SKIPS AT HIGHER SPEED Incorrect ignition timing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer Carburetor maladjusted- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -readjust carburetor Faulty spark plugs- - - - - - - - - - - - - - check spark p[...]

42 STANDARD SERVICE PARTS LIST MODEL ZTR 6023: Blades: Lo-Lift P/N 60293 (standard) Blades: Hi-Lift P/N 60295 Serpentine Belt: P/N 60194 (48”) P/N 61086 (60”) Engine to Hydros: P/N 61101 Clutch to Driveshaft: P/N 60187 Hydrostatic Transmission Filter: P/N 7252 KOHLER AIR AND OIL FILTER PART NUMBERS: Refer to engine manufacturers manual for reco[...]

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

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 6000 Series Model 6023 Part No. 13090-0601 W W W W W ARNING: ARNING: ARNING: ARNING: ARNING: The engine exhaust[...]