Dixon 13090-0700 Lawn Mower User Manual
Contents
1. Reconnect Transmission shift arm disconnected 4 Reconnect Transmission oil low Add oil Transmission locks in free wheel position Put in lock position see pg 19 Hydrostat oil filter plugged Replace filter Bad transmission enne enne Consult dealer Gear mating transmission gearbox disconnected Consult dealer Air in transmission ne Bleed air Not enough tension on drive Check MOWER LOSES POWER TRANSMISSION OVERHEATS Hydrostat transmission oil too low or too high Add Oil or drain oil as needed Transmission Consult dealer Transmission blowing oil out Cap2. Overfilled or water contaminated ENGINE STALLS WHEN BLADES ARE ENGAGED Operator not on Seat nne nne nn nne ne nn nan Sit on seat Faulty interlock SyStemM Consult dealer Bad blade spindle bearing Consult dealer Deck drive belt not properly routed Reroute Blades blocked by foreign material Clean under deck See engine manuals for engine adjustments Page 37 NOTES Page 38 OWNER INFORMATION DATEPURCHASED DIXON INDUSTRIES INC ABLOUNT InternationalInc Co POBOX 1569 COFFEYVILLE KS 67337 0945 316 251 2000 3162514117 MOWER MODEL NUMBER MOWER SERIALNUMBER PURCHASED FROM Name Address DATE OIL CHANGED DATE ENGINE TUNED Page 39 ZIR Mowers 1 W 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
3. Hydrostatic ransmission Oil Reservoir i io T X Check the oil level in hydrostatic transmission oil reservoir after 3 every 25 hours of usage Do not remove the reservoir cap to 5 check the oil level as this allows dirt to enter the transmission 4 Replenish as needed with 20W 50 Mobil Super H D Nh A Wipe area of oil reservoir cap clean of dirt amp debris B Remove oil reservoir cap C Fill to line marked on reservoir ee D Do not overfill Filter E When check oil level be very careful to keep the reservoir clean and fill only with clean oil Change the oil in the reservoir and hydrostat transmission oil filter after the first 200 hours of use Then every 500 hours after that Remove the filter and be sure all oil has drained from the reservoir Replace with new filter and 20W 50 Mobil Super Il Please dispose of used oil at proper collection centers protect your environment Page 25 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 See pic
4. Slow down on rough terrain ENGINE OVERHEATED Air intake screen or fins clogged Clean Intake screen and fins Fuel mixture too Consult dealer Oil level too low or too high rnnt nn nM Adjust oil level Improper ignition timing nen aa nan anana naman ana nan aa aan ln m mr Consult dealer Running engine too SIOW Run engine faster NOTE Always mow at full throttle setting ENGINE IDLES POORLY Carburetor maladjustment 4 Consult dealer Improper spark plug Check and re gap plug ENGINE BACKFIRES Carburetor maladjustment 4 4 Consult dealer ENGINE RUNS BUT MOWER WON T MOVE FORWARD Drive belt broken or slipping Re tension or replace Shift linkage
5. E A E 3 2 ew awa PA T wi JA NAN No NEUTRAL SLOW FAST 90 FORWARD FORWARD RIGHT REVERSE TURN LEFT TURN OPPOSITE TO GO FORWARD From neutral position gently push both drive levers forward To increase speed move levers farther forward TO GO BACKWARD From neutral position gently pull both drive levers toward you TURNING Turning is controlled by moving one drive lever slightly forward or rearward of the other To turn left move left lever rearward of the right lever To turn square corners move lever of desired direction to neutral 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 release levers to neutral set parking brake Park only on level surfaces CHOKE CONTROL LEVER Located on control panel to operator s left Used to start a cold engine THROTTLE CONTROL LEVER Located on control panel to operator s right Controls engine speed slow to maximum While mowing throttle control should be set to the MAXIMUM or wide open setting to insure adequate cooling of the engine and to maintain mower deck blade speed Page 15 CONTROLS BLADE DRIVE Located on the control panel to the operator s right To engage blades pull switch up To disengage blades push switch down CIRCUIT
6. TIRES RECOMMENDED TIRE PRESSURE CAPACITIES DIMENSIONS NOTE SPECIFICATIONS 6000 Series Forward Mount Sheet metal construction frame Folded sheet metal Seat lifts up for access to battery and belt service Designed for operator comfort by use of high density closed cell foam padded back and arm rests upholstered with Cordura water repellent fabric Seat is adjustable fore and aft 2 Decks are available 60 amp 48 are made of 12 GA fabricated welded construction with 10 GA reinforcement plate 3 blades combine for either a 60 cut width Cut height approximately 1 to 5 via 9 position ift handle Electric clutch Each rear wheel is_ independently driven by a HydroGear BDU 10L Series 70 hydrostatic transmission The hydrostatic transmissions in turn power a fully enclosed HydroGear gearbox 22HP Kohler Command 4 Cycle V Configuration Overhead Valve Air Cooled Gasoline Horizontal 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 Electric by key switch operation with safety interlocks on parking brake and blade drive clutch Front 4 10x3 50x4 Rear 5 00 6x13 Drive 20 10 0x10 Front 16 lbs Rear 12 lbs Fuel 5 gallons Hydrostat oil tank 3 quart with in line 40 micron filter Hydrostat oil recommendation re
7. Page 8 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 seriously 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 SAFETY SERVICE Useextra carein handling gasoline and other fuels They areflammable and vapors are explosive Useonly anapproved container Never remove gas cap oradd fuel with the engine running Allow engine to cool before refueling Do notsmoke Neverrefuel the mower indoors Never storethe mower orfuel containerinside a building wherethere 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 containers on the ground away from your vehicle before filling When practical remove gas powered equipment from the truck or tr
8. dealer for carburetor service ENGINE STARTS BUT CUTS OUT Water in gasoline namar mm drain old gasoline replace with new gasoline and or clean carburetor bowl Clogged fuel lies iecore nece ete clean carburetor bowl and or check fuel filter Vent in fuel cap plugged check vent Faulty fuel 2 111 11 aan aa nnn aa aaa consult dealer Maladjusted carburetor readjust carburetor Engine dies when control levers are moved parking brake set release brake ENGINE KNOCKS Low oil level check and add oil Ignition timing Off nEE consult dealer Fuel octane 00 e aa e drain and replace with higher octane gasoline Over heated engine e dc aa shut off engine and allow to cool See engine manual for engine adjustments TROUBLESHOOTING ENGINE SOMETIMES SKIPS AT HIGHER SPEED Incorrect ignition timing eL an nee man aa aaa aa naman an nan ana aa an m nur nr n Consult dealer Carburetor maladjusted Readjust carburetor Faulty spark 5 Check spark plug or condition and reset gap Bouncing off seat safety 6
9. mower BEFORE OPERATING MOWER 1 Read engine manufacturer s operating and maintenance instructions 2 Discuss proper maintenance with your dealer 3 Read and observe all safety instructions on your mower and in the manual 4 Check engine oil 5 Check gas cap to be sure it is in place 6 Be sure parking brake is on 7 Mower blade drive is off 8 Know how to stop engine Turn key to off position Page 17 OPERATION INSTRUCTIONS A TESTING OF SAFETY INTERLOCK SYSTEMS PARKING BRAKE SWITCH TEST With parking brake in the ON position start the engine With the engine running pull one control lever out of the neutral position The engine should stop Repeat for the other control lever then repeat pulling both control levers out of neutral at the same time In all cases the engine should stop BLADE DRIVE SWITCH TEST Electric Clutch or Manual Drive a With either electric blade drive switch turned on or manual lever turned forward parking brake in On position engine should not turn over or attempt to start when key switch is moved to the start position b Ina SAFE AREA away from bystanders start the engine place throttle setting at maximum or full Engage the blade drive either through the electric clutch switch or by turning the manual lever forward Raise weight slightly off of seat Engine should stop c If any Safety Check fails do not operate the mower until the system has been checked and
10. other than those supplied by Dixon Industries Inc VOIDS ALL WARRANTY The following items not covered by this warranty policy a Pick up and delivery charges for transportation of mower to and from an Authorized Dixon dealers place of business b Routine maintenance or adjustments c Belts cutting blades HydroGear filters d Engines All engines used on Dixon ZTR mowers are warranted by each individual engine manufacturer e Any costs or expense of providing substitute equipment while repair work is being performed on a warranted mower There is other express warranty Implied warranties including those of merchantability and fitness for a particular purpose are limited to the same duration of the express warranty and to the extent permitted by law any and all implied warranties are excluded Liabilities for consequential damages under any and all warranties are excluded Blue Customer Yellow Dealer White Dixon WARRANTY VALIDATION Atthe time of sale selling dealer must review each portion of this warranty document complete the information section below secure customer s signature amp send copy to Dixon Industries Inc DATE OF PURCHASE MODEL S N Owner s Name Dealership Address Address Owner s Signature Dealer s Signature Page 10 CHASSIS BODY SEAT MOWER DECK BLADE DRIVE DRIVE SYSTEM ENGINE STARTING SYSTEM
11. repaired by an Authorized Dixon ZTR Dealer Page 18 OPERATION INSTRUCTIONS STARTING INSTRUCTIONS Cold Engine 1 Push choke control lever fully forward 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 move choke control lever to the fully closed position 5 Move throttle control lever to the wide open or maximum setting for actual operation of the mower deck 6 Engine must be operated at wide open or maximum setting to insure adequate lubrication cooling and cut quality of the mower deck Note 6000 Series mowers will require a slightly longer warm up period using partial choke settings UNLOCK TRANSMISSION REARTIRE The freewheel 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 TRANSMISSION 4 RELEASEVALVE si NOTE The tractor should never be FREEWHEELLEVER pulled at more than 2 miles per hour or forany appreciable distance Page 19 OPERATION INSTRUCTIONS STARTING INSTRUCTIONS Engine has been operated 1 Move throttle control lever to 1 4 to 1 2 setting 2 Insert i
12. the lockwasher and prevent loosening of the tension adjust bolt Page 27 CARE AND MAINTENANCE STEERING CONTROL ADJUSTMENTS Page 28 To Adjust Neutral oN e Remove the fender skirts from each side of the machine Block up the unit so that the Drive Wheels are off the ground Start the engine and run at a fast idle with the Steering control levers in the out position 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 Adjust the Neutral Position by turning the rod in the upper linkage until the wheel stops turning Retighten the nuts on the Upper Linkage Assembly and check to see that the drive wheel is still not turning Repeat steps 1 6 for the other side Shut off engine before removing the blocks To Adjust IN Position of the Steering Controls e oo e 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 To Align Handles Sit on the seat and push the control levers full forward and full backward If the ends do not match the handles may be adjusted as follows 1 Locate setscrew stops in the steering control leve
13. to the operator or bystander BLADE CONTACT RUNOVER BACK OVER read and understand this manual to prevent injuries Page 4 SAFETY SYMBOLS oafety Alert Symbol When you see this symbol BE ALERT to the potential for injury Follow recommended safety precautions and safe operating practices Dang A DA NG R indicates an er E situation which if not avoided will result in death or serious injury W AWA R N NG indicates a Bere situation which if not avoided could result in death or serious injury Cauti AN CA U T O N indicates a ee situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices Page 5 SAFETY This cutting moweris capable of amputating hands amp feet and throwing objects Failure to observe thefollowing safety instructions could result in serious injury or death GENERAL OPERATION Read understand andfollow all instructions inthe manual and on the mower before starting Onlyallow 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 Stop mower if anyone enters the area Never carry passengers Donotmowin reverse unless absolutely
14. A 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 Tires may lose traction on slopes even though the brakes are functioning properly Use extra care with grass catchers or other attachments 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 Avoid starting orstopping ona slope Iftires 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 Page 7 SAFETY CHILDREN
15. BREAKER Located on the control panel to the operator s right Protection of the electrical system is 2 30 circuit breakers If circuit breaker trips push button to reset If this condition repeats consult dealer for inspection and repair MOWER DECK CUT HEIGHT LIFT LEVER Located to the right and front of the operator Controls the cutting height Nine positions of adjustment Depress trigger and move lever forward to lower deck Depress trigger and pull lever back to raise deck NOTE To achieve a 1 to 3 cutting range the bar connecting the deck lift handle and the rear of the deck must be in the first hole To achieve a 3 to 5 range the bar connecting the deck lift handle and the rear of the deck must be in the second hole NOTE Always use high position for transport Page 16 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 owner will prevent accidents TOWING Towing a trailer or other attachment that is too heavy could damage the drive or cause the mower to become unstable Limit loads to 500 pounds or less on this
16. DRON ZTR Mowers 1998 Operator s Manual 6000 ERIE FORWARD MOUNT IMPORTANT READ CAREFULLY The Dixon ZTR Mower is both easy and fun to operate However 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 in this operator s manual applies to all Dixon ZTR 6000 Series Commercial Mowers Your Dixon dealer will gladly answer any questions See your dealer for warranty service parts and repairs gt lt pi DIKON INDUSTRIES A BLOUNT International Inc PO BOX 1569 COFFEYVILLE KS 67337 0945 316 251 2000 Page 2 INDEX SAFETY deett Pages 4 9 WARRANTY POLICY Page 10 11 SEAT ADJUSTMENT INSTRUCTIONS Page 12 CONTROLS eiecit ipi sit ab a a Pages 13 16 OPERATION INSTRUCTIONS Pages 17 21 CARE AND MAINTENANCE Pages 22 34 STANDARD SERVICE PARTS LIST Page 35 TROUBLESHOOTING Pages 36 37 6000 Series Forward Mount Part No 13090 0700 Page 3 SAFETY RIDING LAWNMOWERS IF IMPROPERLY OPERATED CAN CAUSE SERIOUS INJURY OR DEATH The most common causes of injury
17. GED POSITION USE THIS HANDLE TO HELP DISENGAGE DOWNHANGER NTI BUCK CYLINDER QUICK RELEASE PIN deck lift handle QUICK RELEASE PIN anti buck cylinder LIFT CORNER OF DECK 7 i bs d m 4 3 2 MIDDLEHOLE CN M ONANTI BUCK m CYLINDER HOLDER DECKLIFT BAR DECKLIFTHANDLE CATCH Page 31 CARE AND MAINTENANCE CHECKING 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 in to the upright position see deck servicing for 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 Rotate the deck into the upright position amp remove drain plug from bottom of gearbox 2 Lower deck to drain fluid 3 When the fluid is drained from gearbox raise deck back up and reinsert the drain plug 4 Remove hex head plug from side of gearbox and fill with Automatic Transmission Fluid ATF Fill to bottom of the hole that the plug is removed from 5 Reinstall hex head plug DRAIN PLUG HEX HEAD PLUG Page 32 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 all tire pressure to correct specifications see page 23 2 Place machine on a
18. INDUSTRIES INC ABLOUNT International Inc Co 6000 Series POBOX 1569 6022 COFFEYVILLE KS 67337 0945 Part No 13090 0700 316251 2000 Page 40
19. ND 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 Airintake screen must be kept clean If plugged engine may be seriously damaged by over heating Battery electrolyte is a poisonous and corrosive sulfuric CAUTION acid solution Avoid spilling on skin eyes and clothing BATTERY Check the fluid in the battery at frequent intervals Keep fluid level above the plates in each cell using distilled water OFF SEASON BATTERY STORAGE Identify each cable so cables can be reconnected to correct terminals Disconnect cables from terminals ALWAYS disconnect ground cable first and reconnect last Charge battery DO NOT remove battery from mower Clean top of battery and terminals with baking soda and water TIRES Correct tire pressure is essential for efficient operation of the mower Check tire pressure periodically Inflate tires to the pressure listed below Front tires 16 Ibs Rear tires 12 Ibs Lug nuts or lug bolts should be checked regularly for tightness Page 23 CARE AND MAINTENANCE Stop engine remove ignition key and spark plugs for safety Wear heavy CAUTION 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 ope
20. NTENANCE TILTING THE DECK see diagram page 31 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 Place the deck lift handle in the lowest cutting position Lift the rear corner of deck amp pivot down hanger to disengage Repeat for other side Raise deck lift handle catch rock handle back and forth until quick release pin pulls free with little effort Lift up on the front of the deck until deck rotates past 90 degrees The middle hole on the anti buck cylinder holder will be in line with the slot on the foot deck locking device Use the quick release pin to secure the deck in the upright position LOWER AND REATTACH THE DECK see diagram page 31 Page 30 Rotate the deck back to horizontal position Stand on front of deck and align deck lift bar with deck lift handle rock handle back and forth until quick release pin slips through NOTE the orientation of the holes in the bar The first hole is for low cutting 1 to 3 the second hole is for height cutting 3 to 5 Lift the rear corner of the deck until the down hanger engages the push bar Repeat for other side Reattach the anti buck cylinder Unlatch foot deck locking device and lower the foot deck back to horizontal position AND FOOTDECKINVERTICAL POSITION FOOT DECKLOCKING DEVICE DOWNHANGERIN ENGA
21. T WON T START NO gas refuel and or clean or replace fuel filters Over or under choked adjust choke Spark plug not firing check spark plug condition or reset gap Carburetor maladjustment reset carburetor adjustment consult dealer Ignition Switch consult dealer for carburetor service HARD TO START ENGINE Fuel line 000 01 clean fuel line and check fuel filter Faulty fuel 1 aan aa one anana na nanam aa nn n nene consult dealer Spark plug wire loose or grounded check spark plug wires Spark plug s faulty or improperly gapped check spark plug condition and reset gap Electronic ignition defective e ecce erre oo aan anama consult dealer Dirty or maladjusted carburetor readjust carburetor or consult
22. ach use Clean grass under after each use Check tire every 10 hours Check every 10 hours Sharpen mower a a a a every 10 hours Check air filterelement every 25 hours Check hydrostatic transmission fluid 25 hours Service engine air filter pre cleaner every 25 hours Grease driveline 3 08 every 50 hours Grease Jack shaft oros oe ew wp wo o as every 50 hours Grease deck pivot tube every 50 hours Check adjustment of P T O clutch every 50 hours or if blades do not stop with 7 seconds from switch disengagement Service airfilterelement every 25 hours Change engine crankcase oil every 100 hours 5 hours break in Change engine oil every 100 hours Change hydrostat oil filter 7252 every 500 hours 50 hours break in Change oil in deck annually or every 500 hours Replace airfilterelement every 100 hours Check spark annually or every 200 hours Service annually or every 500 hours Perform these maintenance procedures more frequently under extremely dusty dirty conditions Replace decals when illegible CARE A
23. ailer and refuel it on the ground Ifthis is not possible then refuel such equipment on atrailer with a portable container rather than from a gasoline dispenser nozzle Ifa gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening atall times until fueling is complete Do not use a nozzle lock open device Never run a mower inside a closed area The exhaust fumes are toxic Keep nuts and bolts tight especially blade attachment bolts and keep equipmentin good condition Nevertamper with safety devices Checktheir proper operation regularly Keep mowerfree of grass leaves or other debris buildup Clean up oil or fuel spillage Allow mowerto cool before storing Stopand inspectthe equipmentif you strike an object Repair if necessary before restarting Never make adjustments or repairs with the engine running Grass catcher components are subject to wear damage and deterioration which could expose moving parts orallow objects to be thrown Frequently check components and replace with original equipment parts when 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 afire orexplosion keep sparks and open flames away from battery Before disconnecting the negative ground cabl
24. e make sure all switches are OFF Page 9 DIXON INDUSTRIES INC AIRPORT INDUSTRIAL PARK PO BOX 1569 COFFEYVILLE KS 67337 0945 316 251 2000 FAX 316 251 4117 DIXONLIMITED WARRANTY POLICY COMMERCIAL MODELS Models 6000 amp 7000 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 1 year from the date of purchase or 400 hours whichever comes first Commercial use is specified as use other than or in addition to mowing at owner s primary place of residence DIXON ZTRMOWERS AREWARRANTED AGAINST DEFECTS IN MATERIALS ANDWORKMANSHIP AND PROVIDES FOR REPLACEMENT ORREPAIR OF PARTS INCLUDING LABOR COSTS THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS ANDLIMITATIONS Warranty applies only to original retail purchaser of new and unused mowers and accessories N All Dixon warranty must be accomplished by authorized Dixon dealers and in accordance with Dixon warranty policy and allowances All warranty claims must be approved by Dixon Industries Inc Battery warranty Limited to 90 days from date of purchase 4 Accessories Warranty Grass Catchers Snow Blades Covers etc Limited to 90 days from date of purchase e Warranty does not apply to damage in transit or incidents of misuse negligence accidents or alteration The use of parts or components
25. fer to page 25 Engine 2 qts SAE 10W30 with filter Width 57 1 2 48 Deck 69 1 2 60 Deck Height 45 1 2 Length 96 101 60 ew Weight 960 lbs 48 Deck 1030 Ibs 60 Deck Additional information provided in service instructions underthe individual component SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE Page 11 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 Page 12 CONTROLS CONTROL LOCATIONS Steering Controls Lever Blade Clutch Switch gt Choke Ignition Key Engine Throttle Light Switch Blade Height Adjust Lever Page 13 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 A CAUTION Engage parking brake before starting engine TO SET PARKING BRAKE The hand operated parking brake is located at right hand side of mower To engage brake pull rearward To release brake move lever forward NOTE X Always set parking brake before dismounting Release parking brake before moving mower HYDRO GEAR DRIVE SYSTEM Allows the mower to turn on its own axis zero turning radius Each lever controls one side of the mower NOTE The pressure required to operate the mower is very light Page 14 CONTROLS
26. gnition key and turn to Start position When engine starts release ignition key Key will return to Run position 3 Move throttle control lever to wide open or maximum setting for actual operation of the mower deck NOTE Model ZTR 6022 may require partial choke setting to start even if the engine has been operated for a period of time 4 Engine must be operated at wide open or maximum setting to insure adequate lubrication cooling and cut quality of the mower deck DO NOT operate the engine in an enclosed area due to the A CAUTION harmful exhaust gas produced NOTE On initial operation set throttle at slow speed Engine cannot be restarted when blade is engaged Safety switches stop engine when operator leaves seat while mower blade is engaged Always turn engine off when leaving mower Page 20 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 pages 36 37 1 A CAUTION Be sure that deflector is properly installed on the discharge chute Set engine speed control to the wide open or full setting Do Not Attempt To Cut Grass When It Is Wet Wet grass will clog the underside of the deck and discharge area 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 app
27. level slab of concrete 3 Move blades by hand so all the blades are pointed in the same direction see diagram on page 34 Measure from the blade tip beveled edge to the ground all three blades If there is more than a 3 16 difference from one side to the other the deck should be leveled 4 Remove the clevis pin from the rear of the lift spring rod on the high side The lift spring rod is two parts one threaded into the other Turn the lift spring rod counter clockwise 2 turns Reassemble clevis pin and remeasure Repeat as required to achieve a difference of no more than 3 16 from one side to the other 5 If the deck is level side to side but high or low at the center blade both lift spring rods must be adjusted equal amounts Shortening the lift spring rods will bring the center blade up and lengthening the lift spring rods will let the center blade down Lift Spring Rod ift Spring Clevis Pi Tension Adjust Bolt Page 33 CARE AND MAINTENANCE BLADE TIP DISCHARGESIDE DECK SPINDLE BELT DIAGRAM Top View Page 34 STANDARD SERVICE PARTS LIST MODEL ZTR 6022 BLADES Hi Lift P N 60295 Lo Lift standard P N 60293 BELTS Serpentine Belt P N 60194 48 P N 60186 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 recommendations regarding frequency of
28. lications may require a second cutting Keep The Underside Of The Mower Deck Clean Frequent removal of dried grass and dirt will allow the clippings to discharge correctly Maintain sharp blade s throughout the cutting season GRASS HEIGHT SUGGESTIONS Correct mowing height can reduce weeds and disease by 50 to 80 The following grass cut heights are based on adequate moisture conditions and normal thatch buildup in a healthy lawn Some locations and applications may require slightly different cut heights If in doubt consult your local lawn professional for assistance Grass Types Best Cut Heights Zoysia 2 2 1 2 Blue Grass 11 2 3 Fescue Blends 1 1 27 3 St Augustine Mid South 1 1 2 2 St Augustine Deep South 3 4 Tifton Bermuda 11 2 Centipede 1 1 2 2 Common Bermuda 1 1 2 2 Bahia Argentina Pensacola 2 Page 21 CARE AND MAINTENANCE CAUTION Before performing any maintenance turn off engine allow to cool remove key and disconnect spark plugs 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 Note Page 22 MAINTENANCE SCHEDULE Check drive belts ool every 50 hours 20 hours break in Check crankcase oil level before each use Clean grass from Hydrostat fans and cooling fans before each use Check air intake screen a a after e
29. necessary Always look down and behind before and while backing Beaware ofthe mower discharge direction and do not pointitatanyone Do notoperate 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 Turn off blades when not mowing Stop engine before removing grass catcher or unclogging chute Mow only in daylightor 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 amp unloading Always wear safety goggles or safety glasses with side 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 or counterweights Maintain or replace safety and instruction labels as necessary A VV ARN N G The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Page 6
30. r base which stop the lever in each direction NOTE The one at the rear is the stop for FWD and the one in the front is the stop for REV Adjust setscrew stops so that handles line up together when shifted full forward and full reverse CARE AND MAINTENANCE STEERING CONTROL ADJUSTMENTS continued D Adjusting for Straight Forward Tracking In large open area actuate the control handles into the full forward position If the mower veers in either direction left or right some adjustment is necessary 1 If the mower veers to the right then the right hydrostat needs to be sped up If the mower veers to the left then the left hydrostat needs to be sped up 2 Stop the machine and shut off the engine 3 Slightly loosen the bolt at the lower end of the upper linkage assembly on the side that is slower Using a 1 8 allen wrench turn the setscrew 1 4 turn in It may take several test drives to get the mower to track straight forward 4 Once the tracking is to the operators liking completely tighten the bolt on the control linkage completely tighten the bolt on the control linkage assembly that was loosened earlier 5 Recheck to make sure neutral adjust has not been effected see procedure A FENDERCAP e SETSCREW RODEND BALL ui d LHLOCKNUT TURN THIS ROD TO ADJUST NEUTRAL UPPERLINKAGE ASSEMBLY SETSCREWUSED TO RHLOCKNU 1 LL DJUSTFORWARD x TRACKING OOSENBOLTON LINKAGE Page 29 CARE AND MAI
31. ration To sharpen blades proceed as follows A Remove bolt lock washer and large flat washer mounting blade on shaft Remove blade B Blades should be discarded when worn excessively C Sharpen blade with a hand file electric grinder or blade sharpener Wear gloves and eye protection when sharpening Grind blade at original 25 degree bevel D Check balance of blade by positioning the blade on a nail or blade balance pedestal Grind the blade on the end that is heavier until both sides balance E Install blade flat washer lock washer and bolt Make sure to tighten bolt to 60 ft Ibs NEW BLADE d DANGEROUS When notch starts 25 Degrees discard blade The main hydro drive belt should be checked after the first 20 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 27 for tensioning instructions V BELTS Page 24 LUBRICATION Engine Follow engine manufacturer s recommendation Deck spindles Lubricate with 3 shots only every 100 hours Hydrostatic transmission and filter P T O Shaft Grease every 50 hours Deck lift rod wldt Grease every 50 hours Deck Gearbox See page 32 mmoou p CHECKING amp REPLENISHING OIL IN HYDROSTATIC TRANSMISSION
32. service required for engine oil changes and air filter maintenance Protect your engine investment use only original equipment filters Model ZTR 6022 22HP Air Filter amp Pre Cleaner 78003 Engine Oil Filter 78006 IMPORTANT Some applications extreme dirt conditions or the use of a grass catcher may require that the engine used on the Model ZTR 6022 be fitted with an OPTIONAL Kohler fresh air filter system Listed below are the Kohler kit numbers required to adapt these components to the engine Consult your dealer or a Kohler engine service center for additional information Model ZTR 6022 22HP Check with Kohler Dealer for availability Page 35 36 TROUBLESHOOTING ENGINE WON T TURN OVER Mower blades engaged disengage blades Drive not in neutral move steering control levers to neutral OUT position IS nn replace fuse Dead battery eee aan aan aan namnaman n nn nn nan aan aan aan rennen nee nee anan anaman an charge or replace eue RE consult dealer Ignition switch aa eee ee oon n nan aa aan rennen ee nan n nnne rr n consult dealer SC O AA M consult dealer ENGINE WILL TURN OVER BU
33. ture at right CASTLE NUT COTTER PIN 010 gap between brake disc and brake puck HYDROSTATIC TRANSMISSION Before each use check to be sure that the cooling fins of the hydrostatic transmissions 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 page 25 of this manual SCALPER ROLLER BOLTS Scalper roller bolts should be tightened until the spacer bushing will not turn relative to the scalper bracket to prevent undue wear on the end of the spacer bushing and the scalper bracket The proper torque is from 17 to 20 ft Ibs Page 26 CARE AND MAINTENANCE HYDROSTAT DRIVE BELT TENSION ADJUSTMENT In normal use the hydrostat drive belt tension should be check after the first 20 hours of use for normal wear in and stretch It may be adjusted as follows A Loosen the idler pulley locking nut until the idler pulley can be just moved relative to the mounting bracket B 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 Do not over tighten NOTE If belt is over tightened it will often make a chattering noise C Retighten the slide locking nut Hydrostatic Drive Belt Hydrostatic Drive Pulley CoolingFins D Retighten the tension adjust bolt 1 4 turn to set
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