Dixon Lawn Mower 13090 0601 User Guide

6000 SERIES  
FORWARD MOUNT  
ZTR®  
2002  
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INDEX  
Page  
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11  
Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . . . . . . . .14  
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-17  
Operation Instructions. . . . . . . . . . . . . . . . . . . 18-24  
Care & Maintenance. . . . . . . . . . . . . . . . . . . . . .25-39  
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 40-41  
Standard Service Parts List. . . . . . . . . . . . . . . . . . . .42  
6000 Series Forward Mount  
Part No. 13090-0601  
3
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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.  
4
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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.  
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.  
5
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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.  
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.  
6
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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.  
•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 manufacturers recommendation for wheel  
weights and counterweights.  
Maintain or replace safety & instruction labels as needed.  
The engine exhaust from this product contains chemicals known to the  
WARNING:  
State of California to cause cancer, birth defects or other reproductive  
harm.  
7
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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 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.  
8
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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 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.  
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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.  
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 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  
complete. Do not use a nozzle lock-open device.  
10  
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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.  
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, 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 a fire or explosion keep  
sparks and open flames away from battery.  
Before disconnecting the negative (-) ground cable, make sure all  
switches are OFF.  
11  
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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. Commercial use is specified as use other than, or in addition to, mowing at owners  
primary place of residence.  
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. Warranty applies only to original retail purchaser of new & unused mowers & accessories.  
2. All Dixon warranty must be accomplished by authorized Dixon dealers & in accordance with  
Dixon warranty policy & allowances. All warranty claims must be approved by Dixon Industries,  
Inc.  
3. 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.  
5. Warranty does not apply to damage in transit or incidents of misuse, negligence, accidents, or  
alteration. The use of parts or components other than those supplied by Dixon Industries, Inc. VOIDS  
ALL WARRANTY.  
6. The following items are 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.  
c.  
d.  
Routine maintenance or adjustments.  
Belts/ cutting blades/ hydrostatic filters.  
Engines - All engines used on Dixon ZTR mowers are warranted by the individual engine  
manufacturer.  
Any costs or expense of providing substitute equipment while repair work is being  
performed on a warranted mower.  
e.  
7. There is no 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 Ind.  
WARRANTY VALIDATION: At the time of sale, selling dealer must review each portion of this warranty  
document, complete the information section below, secure customers signature & send copy to Dixon  
Industries, Inc.  
DATE OF PURCHASE____________________MODEL___________________S/ N_______________  
_____________________________________  
Owners Name  
______________________________________  
Dealership  
_____________________________________  
Address  
______________________________________  
Address  
______________________________________  
_______________________________________  
_____________________________  
______________________________  
12  
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SPECIFICATIONS  
6000 Series Forward Mount  
CHASSIS:  
BODY:  
Sheet metal construction frame.  
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 aft.  
MOWER DECK:  
Two decks are available. Both are made of 12 GA fabricated welded  
construction with 10 GA reinforcement plate. Three blades  
combine for either a 48” or 60” cut width. Cut height approximately 1”  
to 5” via 9 position lift handle.  
BLADE DRIVE:  
Electric clutch.  
DRIVE SYSTEM: 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.  
ENGINE:  
23 HP 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.  
STARTING SYSTEM: Electric by key switch operation with safety interlocks on parking brake  
and blade drive clutch.  
TIRES:  
Front 4.10 x 3.50-4  
Rear 6.00 x 13.00-5  
Drive 10.0 x 10.00-20  
RECOMMENDED Front  
TIRE PRESSURE: Rear  
16 lbs.  
12 lbs.  
CAPACITIES:  
Fuel - 5 gallons  
Hydrostat oil tank - 3 quart with in-line 40 micron filter  
Hydrostat oil recommendation, refer to page 29  
Engine - 2 quarts SAE 10W30 (with filter)  
DIMENSIONS:  
Width  
57-1/ 2(48” Deck) 69-1/ 2” (60” Deck)  
Height 45-1/ 2”  
Length 96” (48” Deck), 101” (60” Deck)  
Weight 960 lbs. (48” Deck), 1030 lbs. (60” Deck)  
Additional information provided in service instructions under the individual component.  
13  
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SEAT ADJUSTMENT INSTRUCTIONS  
6000 SERIES  
1 .  
Grasp seat slide adjuster and move  
it into adjustment position.  
Slide seat forward or backward.  
Release seat slide adjuster.  
2 .  
3 .  
14  
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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.  
To turn right, move right lever rearward of the left lever.  
To turn on mowers 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.  
15  
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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.  
HYDRO-GEAR DRIVE SYSTEM:  
Allows the mower to turn on its own axis (zero turning  
radius).  
Each lever controls one side of the mower.  
16  
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CONTROLS  
MOWER BLADE SWITCH:  
Located on the control panel to the operators right.  
To engage blades: pull up on switch  
To disengage blades: push down  
CHOKE CONTROL LEVER:  
Located on control panel to operators left. Use to start a cold engine.  
THROTTLE CONTROL LEVER:  
Located on control panel to operators right. Controls engine speed, slow  
to maximum.  
While mowing, throttle control should be set to MAXIMUM or  
wide open setting to insure adequate cooling of the engine and  
to maintain mower deck blade speed.  
CIRCUIT BREAKER:  
Located on control panel to the operators right. Protection of the  
electrical system is by (2) 30 amp circuit breakers.  
If circuit breaker trips, push button to reset.  
If condtion 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.  
17  
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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.  
TOWING  
Towing a trailer or other attachment that is too heavy could damge  
the drive or cause the mower to become unstable. Limit loads to  
500 pounds or less with this mower.  
BEFORE OPERATING MOWER:  
1.  
Read and observe all safety instructions on your  
mower and in the manual.  
2.  
Read engine manufacturers operating and  
mainte nance instructions.  
3.  
4.  
5.  
6.  
7.  
Check engine oil.  
Check fuel cap to be sure it is in place.  
Be sure parking brake is on.  
Be sure that mower blade drive is off.  
Know how to stop engine. (Turn key to off position).  
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OPERATION INSTRUCTIONS  
INTERLOCK SWITCH TEST  
Note: Operator must be seated in normal operating position to  
perform these tests.  
1.  
2.  
3.  
With engine off, turn mower blade on and attempt to  
start engine.  
ENGINE SHOULD NOT START.  
With engine off, move control levers in and attempt to  
start engine.  
ENGINE SHOULD NOT START  
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.  
ENGINE SHOULD STOP.  
4.  
With engine running, set parking brake and move  
levers inboard.  
ENGINE SHOULD STOP.  
If any safety check fails, do not operate the mower until the  
system has been checked and repaired by an authorized  
Dixon ZTR dealer.  
19  
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OPERATION INSTRUCTIONS  
STARTING INSTRUCTIONS (cold engine):  
1.  
Operator must be seated in normal operating position.  
2.  
3.  
4.  
5.  
Set parking brake.  
Push choke control lever fully foward.  
Push throttle control lever to 1/ 2 setting.  
Insert ignition key and turn to start” position. When engine  
starts, release ignition key. Key will return to run” position.  
6.  
7.  
8.  
Once engine starts to warm up, slowly move choke control lever to  
the fully closed position.  
Move throttle control lever to the wide open or maximum setting  
for actual operation of the mower deck.  
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.  
CAUTION  
Do not operate the engine in an enclosed area  
due to the harmful exhaust gas produced.  
20  
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OPERATION INSTRUCTIONS  
STARTING INSTRUCTIONS (engine has been operated):  
1.  
Operator must be seated in normal operating position.  
2.  
3.  
5.  
Set parking brake.  
Push throttle control lever to 1/ 4 to 1/ 2 setting.  
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.  
Note: Model 6023 may require partial choke setting to insure  
adequate engagement of the mower deck. As engine  
warms, open choke lever.  
7.  
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.  
CAUTION  
Do not operate the engine in an enclosed area  
due to the harmful exhaust gas produced.  
Notes: On initial operation, set throttle at slow speed.  
Engine cannot be restarted when blades are engaged.  
Safety switches stop engine when operator leaves seat while  
mower blades are engaged.  
Always turn engine off when leaving mower.  
21  
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OPERATION INSTRUCTIONS  
MOWING INSTRUCTIONS:  
CAUTION Be sure that deflector is properly  
installed on the discharge chute.  
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 Check the area to assure there is no  
one near.  
5 .  
Engage mower blades.  
22  
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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. THE  
TRACTOR SHOULD NEVER BE PUSHED  
OR PULLED OVER TWO (2) MPH FOR  
ANY APPRECIABLE DISTANCE.  
23  
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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.  
Correct mowing height can reduce weeds and disease by  
50% to 80%.  
The following grass cut heights are based an adequate  
moisture conditions and normal thatch build-up 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  
Bermudagrass  
Bluegrass  
Buffalograss  
Ryegrass  
Tall Fescue  
Zoysiagrass  
1 - 2”  
2 - 3”  
11/ 2 -3”  
2 - 3”  
3-31/ 2  
1 - 3”  
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CARE AND MAINTENANCE  
CAUTIO N  
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .after each use  
Clean grass under deck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . after each use  
Check tire pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . every 10 hours  
Check mower blades for sharpness. . . . . . . . . . . . . . . . . . . . . . . every 10 hours  
Check air filter element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . every 10 hours  
Service air filter element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .every 25 hours  
Check hydrostatic transmission fluid. . . . . . . . . . . . . . . . . . . . . . .every 25 hours  
Service engine air filter pre-cleaner. . . . . . . . . . . . . . . . . . . . . . . .every 25 hours  
Grease driveline (3 fittings). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . every 50 hours  
Grease jack shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 within 7 seconds  
from switch disengagement)  
Check all belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . every 50 hours  
(20 hours break-in)  
Replace air filter element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . every 100 hours  
Change engine crankcase oil and filter. . . . . . . . . . . . . . . . . . .every 100 hours  
(5 hours break-in)  
Check spark plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . .annually or every 200 hours  
Change oil in deck gearbox. . . . . . . . . . . . . . . . . . .annually or every 500 hours  
Change hydrostat oil & oil filter (7252). . . . . . . . . . . . . . . . . . .every 500 hours  
(100 hours break-in)  
Perform these maintenance procedures more frequently under  
extremely dusty , dirty conditions. Replace decals when illegible.  
25  
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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  
poisonous and corrosive.  
CAUTION  
This is a maintenance-free battery and the fluid level cannot  
be checked.  
Charge battery if required.  
OFF SEASON BATTERY STORAGE:  
DO NOT remove battery from mower.  
Clean top of battery and terminals with baking soda and water.  
Identify each cable so they can be reconnected to the correct  
terminal.  
Disconnect cables from terminals. ALWAYS disconnect ground  
cable first and reconnect last.  
Charge battery.  
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  
Rear tires  
-
-
16-20 lbs.  
8-14 lbs.  
Lug nuts or lug bolts should be checked regularly for tightness.  
26  
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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.  
3.  
Blades should be discarded when worn excessively.  
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.  
4.  
5.  
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.  
Install blade, flat washer & bolt. Make sure to tighten  
bolt to 60 ft. lbs.  
DANGEROUS!  
DO NOT USE  
BLADE IN THIS  
CONDITION!  
New Blade  
When notch starts,  
discard blade  
27  
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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.  
Engine: Follow engine manufacturers  
recommendation.  
Deck spindles: Lubricate with 3 shots” only,  
every 100 hours.  
C.  
D.  
E.  
F.  
Hydrostatic transmission and filter.  
P.T.O. Shaft: Grease every 50 hours.  
Deck lift rod weldment: Grease every 50 hours.  
Deck Gearbox: See page 31.  
SCALPER ROLLER BOLTS:  
Scalper roller bolts should be tightened until the spacer  
bushing will not run 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. lbs.  
28  
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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. Do not remove the reservoir  
cap to check the oil level as this allows dirt to enter the  
transmission. Replenish as needed with SAE 20W-50  
motor oil. Any high quality engine oil with an API classification  
Hydrostatic  
of SG/ CD is recommended.  
Transmission  
Oil Reservoir  
A. Wipe area of oil reservoir cap  
clean of dirt & debris.  
B. Remove oil reservoir cap.  
C. Fill to line marked on reservoir.  
D. Do not overfill.  
E. When checking oil level, be very  
careful to keep the reservoir  
clean and fill only with clean oil.  
Hydrostatic Transmisson  
Filter  
Change the oil in the reservoir  
and hydrostat transmission oil filter  
after the first 100 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  
Dixon filter P/ N 7252 and SAE 20W-50  
motor oil.  
29  
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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 picture below.  
CASTLE NUT  
COTTER PIN  
0.10 GAP BETWEEN BRAKE DISC AND  
30  
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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. Rotate the deck into the upright position & 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 remov
5. Reinstall hex head plug.  
DRAIN PLUG  
HEX HEAD PLUG  
GEARBOX  
31  
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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. Do not over tighten.  
Note: If belt is over-tightened it will often make a “chattering”  
noise.  
3.  
Retighten the slide locking nut.  
Motor Pulley  
Tension Adjust Bolt  
Hydrostatic Drive Belt  
Idler Pulley  
Hydrostatic Drive Pulley  
Cooling Fins  
4.  
Retighten the tension adjust bolt 1/ 4 turn to set the  
lockwasher and prevent loosening of the tension  
adjust bolt.  
32  
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CARE AND MAINTENANCE  
STEERING CONTROL ADJUSTMENTS:  
To adjust neutral:  
1.  
2.  
3.  
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.  
4.  
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.  
Adjust the neutral position by turning the rod in the  
upper linkage until the wheel stops turning.  
Retighten the nuts on the upper linakge assembly and  
check to see that the drive wheel is still not turning.  
Repeat steps 1-6 for the other side.  
7.  
8.  
Shut off engine before removing the blocks.  
33  
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CARE AND MAINTENANCE  
STEERING CONTROL ADJUSTMENTS (continued):  
To adjust IN” position of the steering controls:  
1.  
2.  
3.  
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.  
4.  
5.  
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.  
2.  
Locate setscrew stops in the steering control lever  
base which stop the lever in each direction.  
Note: The one at the rear is the stop for forwad and  
the one in the front is the stop for reverse.  
Adjust setscrew stops so that handles line up  
together when shifted full forward and full reverse.  
34  
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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.  
2.  
3.  
Stop machine and shut off engine.  
Slightly loosen bolt at lower end of upper linkage  
assembly on 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 mower to track straight  
forward.  
4.  
5,  
Once the tracking is to the operators liking, completely  
tighten the bolt on the control linkage assembly that  
was loosened earlier.  
Recheck to make sure neutral adjust has not been  
affected.  
Fender  
Ca p  
Forward S
Setscrew  
Reverse Stop  
Setscrew  
Rod End  
Ball Joint  
Setscrew used to  
Adjust Forward  
Tracking  
LH Locknut  
Upper Linkage  
Assembly  
n Bolt  
nkage  
RH Locknut  
35  
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CARE AND MAINTENANCE  
TILTING THE DECK (see diagram-page37)  
1.  
2.  
Set the parking brake.  
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.  
5.  
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.  
6.  
7.  
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 & REATTACH THE DECK(see diagram-page 37)  
1.  
2.  
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 high cutting 3" to 5".  
3.  
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.  
4.  
5.  
36  
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CARE AND MAINTENANCE  
DOWN HANGER IN  
ENGAGED POSITION  
FOOT DECK IN  
VERTICAL POSITION  
K  
EVICE  
USE THIS HANDLE TO HELP  
DISENGAGE DOWN HANGER  
ANTI-BUCK  
CYLINDER  
QUICK
(deck li
QUICK RELEASE  
PIN (anti-buck  
cylinder)  
LIFT CORNER  
OF DECK  
HOLE  
TI-BUCK  
ER  
R  
DECK LIFT HANDLE CATCH  
DECK LIFT BAR  
DECK LIFT TUBE  
(Lift Assist Bar Inside)  
37  
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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.  
3.  
Place machine on a level slab of concrete.  
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. If there is more  
than a 3/ 16" difference from one side to the other, the deck  
should be leveled.  
4.  
5,  
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 re-measure. Repeat as required to  
achieve a difference of no more than 3/ 16" from one side to the  
other.  
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  
Lift Spring  
Clevis Pin  
Tension Adjust Bolt  
38  
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CARE AND MAINTENANCE  
BLADE  
DISCHARGE SIDE  
DECK SPINDLE BELT DIAGRAM  
(TOP VIEW)  
39  
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TROUBLESHOOTING  
1.  
ENGINE WON’T TURN OVER  
Mower blades engaged- - - - - - - - - - - - - - - - - - - - - - -disengage blades  
Drive not in neutral - - - - - - - - - - - - - - - - - - move control levers to neutral OUT”  
Breaker trips- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - reset breaker  
Dead battery- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - charge or replace  
Solenoid- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Ignition switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Starter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Parking brake not on- - - - - - - - - - - - - - - - - - - - -engage parking brake  
2.  
3.  
ENGINE WILL TURN OVER BUT WON’T START  
No fuel- - - - - - - - - - - - - - - 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 clogged- - - - - - - - - - - - - clean fuel line and check fuel filter  
Faulty fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Over or under choke- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -adjust choke  
Spark plug wire loose or grounded- - - - - - - - -check spark plug wire  
Spark plugs faulty / improperly gapped- - - -check plugs/ condition/ reset gap*  
Electronic ignition defective- - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Dirty or maladjusted carburetor- - - - - - - - readjust */ consult dealer for service  
4.  
ENGINE STARTS BUT CUTS OUT  
Water in fuel- - - - - - - - - - - - - - - -drain old fuel-replace with new fuel  
Clogged fuel line- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -check fuel filter  
Fuel tank vent plugged- - - - - - - - - - - - - - - - - - - - - - - - - - - -clean fuel line  
Faulty fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - check vent  
Engine dies when control levers moved IN- - - - - - - - - - - - -release parking brake  
5.  
6.  
ENGINE KNOCKS  
Low oil level- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - check and add oil  
Ignition timing off- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Fuel octane too low- - - - - - - - - - - - - - - - -drain and replace with higher octane fuel  
Over heated engine- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - shut off and allow to cool  
ENGINE IDLES POORLY  
Carburetor maladjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Improper spark plug gap- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -check and re-gap plug*  
Choke stuck on- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - check or adjust  
*See engine manual for adjustments  
40  
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TROUBLESHOOTING  
7.  
8.  
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  
ENGINE OVERHEATED  
Air intake screen or fins clogged- - - - - - - - - - - - - - - - - clean intake screen and fins  
Fuel mixture too lean- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Oil level too low or too high- - - - - - - - - - - - - - - - - - - - - - - - - - - adjust oil level  
Improper ignition timing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Running engine too slow- - - - - - - - - - - - - - - - - - - - - - - - - -run engine faster  
NOTE: Always mow at full throttle setting!  
9.  
ENGINE BACKFIRES  
Carburetor maladjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
10.  
ENGINE RUNS BUT MOWER WON’T MOVE FORWARD  
Free wheel levers engaged- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -release levers  
Drive belt broken or slipping- - - - - - - - - - - - - - - - - - - - - - -replace drive belt  
Shift linkage cable disconnected- - - - - - - - - - - - - - - - - - - - - - - - -reconnect  
Transmission shift arm disconnected- - - - - - - - - - - - - - - - - - - -reconnect  
Transmission oil low- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - -add oil  
Transmission locks in free wheel position- put in lock position(see pg.23)  
Hydrostat oil filter plugged- - - - - - - - - - - - - - - - - - - - - - - - - - - - replace filter  
Bad transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Gear mating transmission/ gearbox disconnected- - - - - - -consult dealer  
Air in transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - bleed air  
Not enough tension on drive belt- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -check belt  
11.  
12.  
MOWER LOSES POWER OR TRANSMISSION OVERHEATS  
Hydrostat transmission oil too low or high- - -add oil or drain as needed  
Transmission damage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - --consult dealer  
Transmission blowing oil out cap- - - - overfilled or water contaminated  
ENGINE STALLS WHEN BLADES ARE ENGAGED  
Operator not on seat- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -sit on seat  
Faulty interlock system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -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 manual for engine adjustments  
41  
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STANDARD SERVICE PARTS LIST  
MODEL ZTR 6023:  
Blades:  
Blades:  
Lo-Lift P/ N 60293 (standard)  
Hi-Lift P/ N 60295  
Serpentine Belt:  
P/ N 60194 (48)  
P/ N 61086 (60)  
P/ N 61101  
Engine to Hydros:  
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 service required for engine oil changes and air filter  
maintenance.  
Protect your engine investment, use only original equipment filters.  
MODEL ZTR 6023 (23 HP):  
Air Filter & Pre-Cleaner Kit  
Engine Oil Filter  
78003  
78006  
IMPORTANT:  
Some applications, extreme dirt conditons, or the use of a grass  
catcher may require that the engine used on the Model 6023 be  
fitted with an OPTIONAL Kohler fresh air filter system. Consult your  
dealer or a Kohler engine service center for the part numbers  
required to adpat these components to the engine or for additional  
information.  
42  
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OWNER  
INFORMATION  
DIXON INDUSTRIES, INC.  
a BLOUNT International Inc. Co.  
P.O. Box 1569  
Coffeyville, Ks 67337-0945  
620-251-2000  
FAX 620-251-4117  
Date Purchased _________________________________  
Mower Model Number ____________________________  
Mower Serial Number ____________________________  
Purchased From ________________________________  
Name  
________________________________  
Address  
________________________________  
DATE OIL CHANGED:  
DATE ENGINE TUNED:  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
43  
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ZTR®Mowers  
The engine exhaust from this product contains chemicals known  
to the State of California to cause cancer, birth defects or other  
reproductive harm.  
WARNING:  
Dixon® and ZTare 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  
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