1998 Operator's Manual
6000
SERIES
FORWARD MOUNT
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INDEX
SAFETY ..........................................................Pages
WARRANTY POLICY .....................................Page
SPECIFICATIONS ..........................................Page
SEAT ADJUSTMENT INSTRUCTIONS......... Page
CONTROLS ....................................................Pages
OPERATION INSTRUCTIONS.......................Pages
CARE AND MAINTENANCE ..........................Pages
STANDARD SERVICE PARTS LIST .............Page
TROUBLESHOOTING ...................................Pages
4-9
10
11
12
13-16
17-21
22-34
35
36-37
6000 Series Forward Mount
Part No. 13090-0700
Page 3
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SAFETY
RIDING LAWNMOWERS, IF IMPROPERLY OPERATED,
CAN CAUSE SERIOUS INJURY OR DEATH
The most common causes of injury to the operator or bystander...
BLADECONTACT
TIP-OVER
RUNOVER
BACK-OVER
...read and understand this manual to prevent injuries.
Page 4
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SAFETY
SAFETY SYMBOLS
SafetyAlert Symbol
When you see this symbol,
BE ALERT to the potential for injury.
Followrecommendedsafetyprecautionsandsafe
operatingpractices.
Danger
indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury.
Warning
indicates a potentially hazardous situation
which, if not avoided, could result in death
or serious injury.
Caution
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.
Page 5
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SAFETY
Thiscuttingmoweriscapableofamputatinghands&feet,andthrowingobjects.
Failuretoobservethefollowingsafetyinstructionscouldresultin
seriousinjuryordeath.
GENERAL OPERATION:
•
•
•
•
•
•
Read,understand,andfollowallinstructionsinthemanualandonthemowerbeforestarting.
Onlyallowresponsibleadults,whoarefamiliarwiththeinstructions,tooperatethemower.
Cleartheareaofobjectssuchasrocks,toys,wire,etc.,whichcouldbepickedupandthrownbytheblade.
Besuretheareaisclearofotherpeoplebeforemowing. Stopmowerifanyoneentersthearea.
Nevercarrypassengers.
Donotmowinreverseunlessabsolutelynecessary. Alwayslookdownandbehindbeforeandwhile
backing.
•
Beawareofthemowerdischargedirectionanddonotpointitatanyone. Donotoperatethemowerwithout
eithertheentiregrasscatcherorthedeflectorinplace.
•
•
Slowdownbeforeturning.
Neverleavearunningmowerunattended. Alwaysturnoffblades,setparkingbrake,stopengine,and
removekeybeforedismounting.
•
•
•
•
•
•
Turnoffbladeswhennotmowing.
Stopenginebeforeremovinggrasscatcheroruncloggingchute.
Mowonlyindaylightorgoodartificiallight.
Donotoperatethemowerwhileundertheinfluenceofalcoholordrugs.
Watchfortrafficwhenoperatingnearorcrossingroadways.
Useextracarewhenloadingorunloadingthemowerintoatrailerortruck. Donotridethemowerwhen
loading&unloading.
•
•
Alwayswearsafetygogglesorsafetyglasseswithsideshieldswhenoperatingmower.
Dataindicatesthatoperators,age60yearsandabove,areinvolvedinalargepercentageofridingmower-
relatedinjuries. Theseoperatorsshouldevaluatetheirabilitytooperatetheridingmowersafelyenoughto
protectthemselvesandothersfromseriousinjury.
•
•
Followthemanufacturer'srecommendationforwheelweightsorcounterweights.
Maintainorreplacesafetyandinstructionlabels,asnecessary.
The engine exhaust from this product contains chemicals known to the State
of California to cause cancer, birth defects or other reproductive harm.
WARNING:
Page 6
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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.
Avoidstartingorstoppingonaslope. Iftireslosetraction,disengagethebladesand
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
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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.
Page 8
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SAFETY
SERVICE:
•
Useextracareinhandlinggasolineandotherfuels. Theyareflammableandvaporsareexplosive.
Useonlyanapprovedcontainer.
Neverremovegascaporaddfuelwiththeenginerunning. Allowenginetocoolbeforerefueling. Do
notsmoke.
Neverrefuelthemowerindoors.
Neverstorethemowerorfuelcontainerinsideabuildingwherethereisanopenflame.
Iffuelisspilledonclothing,changeclothingimmediately.
Topreventfireandexplosioncausedbystaticelectricity:
Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place
containersonthegroundawayfromyourvehiclebeforefilling.
Whenpractical,removegas-poweredequipmentfromthetruckortrailerandrefuelitontheground.
Ifthisisnotpossible,thenrefuelsuchequipmentonatrailerwithaportablecontainer,ratherthanfrom
agasolinedispensernozzle.
Ifagasolinedispensernozzlemustbeused,keepthenozzleincontactwiththerimofthefueltankor
containeropeningatalltimesuntilfuelingiscomplete. Donotuseanozzlelock-opendevice.
•
•
•
•
Neverrunamowerinsideaclosedarea. Theexhaustfumesaretoxic.
Keepnutsandboltstight,especiallybladeattachmentbolts,andkeepequipmentingoodcondition.
Nevertamperwithsafetydevices. Checktheirproperoperationregularly.
Keepmowerfreeofgrass,leaves,orotherdebrisbuildup. Cleanupoilorfuelspillage. Allowmowertocool
beforestoring.
•
•
•
Stopandinspecttheequipmentifyoustrikeanobject. Repair,ifnecessary,beforerestarting.
Nevermakeadjustmentsorrepairswiththeenginerunning.
Grasscatchercomponentsaresubjecttowear,damage,anddeterioration,whichcouldexposemoving
partsorallowobjectstobethrown. Frequentlycheckcomponentsandreplacewithoriginalequipment
parts,whennecessary.
•
•
Mowerbladesaresharpandcancut. Wraptheblade(s)orweargloves,anduseextracautionwhenservicing
them.
Batteriescontainsulfuricacid. Topreventburnsavoidcontactwithskin,eyesandclothing. Toprevent
afireorexplosionkeepsparksandopenflamesawayfrombattery.
•
Beforedisconnectingthenegative(-)groundcable,makesureallswitchesareOFF.
Page 9
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DIXON INDUSTRIES, INC.
a BLOUNT company
AIRPORT INDUSTRIAL PARK
PO BOX 1569
COFFEYVILLE KS 67337 0945
316 251 2000
FAX 316 251 4117
DIXONLIMITEDWARRANTYPOLICY-COMMERCIALMODELS
Models6000&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.
DIXONZTRMOWERS AREWARRANTEDAGAINSTDEFECTSINMATERIALS
ANDWORKMANSHIPANDPROVIDESFORREPLACEMENTORREPAIROFPARTSINCLUDING
LABOR COSTS. THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS
ANDLIMITATIONS:
1. Warranty applies only to original retail purchaser of new and unused mowers and accessories.
2. 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.
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
dealer's 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.
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.
WARRANTYVALIDATION: Atthetimeofsale,sellingdealermustrevieweachportionofthiswarranty
document,completetheinformationsectionbelow,securecustomer'ssignature&sendcopytoDixonIndustries,Inc.
DATEOFPURCHASE
MODEL
S/N
Owner'sName
Address
Dealership
Address
Owner'sSignature
Dealer'sSignature
Page 10
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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:
2 Decks are available. 60" & 48" are made of 12 GA fabricated welded
construction with 10 GA reinforcement plate. 3 blades combine for either
a 48" or 60" cut width. Cut height approximately 1" to 5" via 9 position
lift handle.
BLADE DRIVE:
DRIVE SYSTEM:
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.
ENGINE:
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-
typeFuelPump,FixedJetCarburetorw/Smart-Choke,ElectronicIgnition,
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
Rear
Drive
4.10x3.50x4
5.00-6x13
20-10.0x10
RECOMMENDED
TIRE PRESSURE:
Front
Rear
16 lbs.
12 lbs.
CAPACITIES:
DIMENSIONS:
NOTE:
Fuel - 5 gallons
Hydrostat oil tank - 3 quart with in-line 40 micron filter
Hydrostat oil recommendation, refer to page 25
Engine - 2 qts. SAE 10W30 (with filter)
Width
57-1/2”(48" Deck), 69-1/2"(60" Deck)
45-1/2"
96" (48” Deck), 101” (60” Deck)
960 lbs. (48" Deck), 1030 lbs. (60" Deck)
Height
Length
Weight
Additionalinformationprovidedinserviceinstructionsundertheindividual
component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
Page 11
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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
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CONTROLS
CONTROL LOCATIONS
Steering Controls
Parking B
Lever
Blade Clutch S
Choke
Ignition K
Light Switch
Engine
Throttle
Blade Height
Adjust Lever
Page 13
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CONTROLS
PARKINGBRAKE:
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
CAUTION
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:
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
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CONTROLS
(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:
BRAKING:
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.
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
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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 BREAKER:
Located on the control panel to the operator's right.
Protection of the electrical system is by (2) 30 amp 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
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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 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
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
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OPERATION INSTRUCTIONS
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. In a 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 repaired by an Authorized
Dixon ZTR Dealer.
Page 18
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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.
UNLOCKTRANSMISSION:
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
RELEASEVALVE
NOTE: The tractor should never be
pulled at more than 2 miles per hour or
for any appreciable distance.
FREEWHEELLEVER
Page 19
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OPERATION INSTRUCTIONS
STARTING INSTRUCTIONS:
Engine has been operated.
1. Move throttle control lever to 1/4 to 1/2 setting.
2. Insert ignition 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
harmful exhaust gas produced.
CAUTION
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
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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.
Be sure that deflector is properly installed on the
discharge chute.
CAUTION
1. Set engine speed control to the wide open or full setting.
2. Do Not Attempt To Cut Grass When It Is Wet. Wet grass will clog the underside of the deck
and discharge area.
3. 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.
4. Keep The Underside Of The Mower Deck Clean. Frequent removal of dried grass and dirt will
allow the clippings to discharge correctly.
5. 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
Blue Grass
Fescue Blends
St. Augustine (Mid South)
St. Augustine (Deep South)
Tifton Bermuda
2" - 2 1/2"
1 1/2" - 3"
1 1/2" - 3"
1 1/2" - 2"
3" - 4"
1 1/2"
Centipede
Common Bermuda
Bahia/Argentina/Pensacola
1 1/2" - 2"
1 1/2" - 2"
2"
Page 21
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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.
MAINTENANCE SCHEDULE
every 50 hours
Check drive belts . . . . . . . . . . . . . . . . . . . . . . .
(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. . . . . . . . . . . . . . . . . . . . . after each use
Clean grass under deck . . . . . . . . . . . . . . . . . . . . after each use
Check tire pressure . . . . . . . . . . . . . . . . . . . . . . every 10 hours
Check battery fluid . . . . . . . . . . . . . . . . . . . . . . every 10 hours
Sharpen mower blades . . . . . . . . . . . . . . . . . . . . every 10 hours
Check 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 ifblades do not stop with 7
seconds from switch disengagement)
Service air filter element . . . . . . . . . . . . . . . . . . . .every 25 hours
Change engine crankcase oil. . . . . . . . . . . . . . . . .every 100 hours
(5 hours break-in)
Change engine oil filter. . . . . . . . . . . . . . . . . . . . every 100 hours
Change hydrostat oil filter (7252) . . . . . . . . . . . . . . every 500 hours
(50hours break-in)
Change oil in deck gearbox . . . . . . . . . . . annually or every 500 hours
Replace air filter element. . . . . . . . . . . . . . . . . . . every 100 hours
Check spark plugs. . . . . . . . . . . . . . . . annually or every 200 hours
Service battery . . . . . . . . . . . . . . . . . . annually or every 500 hours
Note: Performthesemaintenanceproceduresmorefrequentlyunderextremelydusty,dirtyconditions.
Replace decals when illegible.
Page 22
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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 over heating.
Battery electrolyte is a poisonous and corrosive sulfuric
acid solution. Avoid spilling on skin, eyes and clothing.
CAUTION
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 lbs.
Rear tires - 12 lbs.
Lug nuts or lug bolts should be checked regularly for tightness.
Page 23
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CARE AND MAINTENANCE
Stop engine, remove ignition key and spark plugs for safety. Wear heavy,
thick gloves when holding onto cutter blade, avoid the sharp
edge of the blade.
CAUTION
MOWER BLADES:
Check sharpness of mower blades after every 10 hours of operation. To sharpen
blades, proceed as follows.
A.
Remove bolt, lock washer, and large flat washer mounting blade on shaft.
Remove blade.
B.
C.
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.
D.
E.
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, lock washer and bolt. Make sure to tighten bolt to 60
ft. lbs.
NEW BLADE
DANGEROUS!
When notch starts
discard blade
25 Degrees
V-BELTS:
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
tensioninginstructions).
Page 24
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CARE AND MAINTENANCE
LUBRICATION:
A.
B.
C.
D.
E.
F.
Engine: Followenginemanufacturer'srecommendation.
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.
CHECKING & REPLENISHING OIL IN HYDROSTATIC
TRANSMISSION
Hydrostatic
Transmission
Oil Reservoir
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 20W-50 Mobil Super H.D.
A.
B.
C.
D.
E.
Wipe area of oil reservoir cap clean of dirt & debris.
Remove oil reservoir cap.
Fill to line marked on reservoir.
Do not overfill.
When check oil level be very careful to keep the
reservoir clean and fill only with clean oil.
Hydrostatic
Transmission
Filter
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 II.
Pleasedisposeofusedoilatpropercollectioncenters-protectyourenvironment
Page 25
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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 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. lbs.
Page 26
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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.
B.
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.
C.
Retighten the slide locking nut.
Motor Pulley
TensionAdjustBolt
Hydrostatic
Drive Belt
Idler Pulley
Hydrostatic
Drive Pulley
CoolingFins
D.
Retighten the tension adjust bolt 1/4 turn to set the lockwasher and prevent loosening
of the tension adjust bolt.
Page 27
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CARE AND MAINTENANCE
STEERING CONTROL ADJUSTMENTS
A.
To Adjust Neutral:
1.
2.
3.
4.
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.
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 Linkage Assembly and check to see that the drive wheel is
still not turning.
7.
8.
Repeat steps 1-6 for the other side.
Shut off engine before removing the blocks.
B.
To Adjust "IN" Position of the Steering Controls:
1.
2.
3.
4.
5.
Remove the two front bolts, lockwashers, and washers which hold the fender cap.
Pull the boot from the hole in the fender cap, exposing the cast iron lever.
Using a 5/32" Allen wrench, turn the setscrew to adjust the stop.
Replace the boot into the hole in the fender cap.
Replace the two front bolts, lockwashers and washers.
C.
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 lever 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.
2.
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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.
3.
Stop the machine and shut off the engine.
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.
5.
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.
Recheck to make sure neutral adjust has not been effected, see procedure A.
ACCESSHOLE
FENDERCAP
REVERSESTOP
SETSCREW
FORWARDSTOP
SETSCREW
RODEND
BALLJOINT
LHLOCKNUT
TURN THIS ROD TO
ADJUSTNEUTRAL
UPPERLINKAGEASSEMBLY
SETSCREWUSEDTO
ADJUSTFORWARD
TRACKING
RHLOCKNUT
LOOSENBOLTON
LINKAGE
Page 29
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CARE AND MAINTENANCE
TILTING THE DECK (see diagram-page 31)
1.
2.
3.
4.
5.
6.
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 & 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.
7.
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)
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 height cutting 3" to 5".
3.
Lift the rear corner of the deck until the down hanger engages the push bar. Repeat for
other side.
4.
5.
Reattach the anti-buck cylinder.
Unlatch foot deck locking device and lower the foot deck back to horizontal position.
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CARE AND MAINTENANCE
FOOTDECKINVERTICAL
POSITION
KING
DOW
ENG
HELP
NGER
KCYLINDER
QUIC
(dec
RELEASEPIN
uckcylinder)
LIFTC
DLEHOLE
NTI-BUCK
YLINDER
OLDER
DECKLIFTHANDLECATCH
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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.
2.
Rotate deck in to the upright position (see deck servicing for procedure).
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.
2,
3.
4.
Rotate the deck into the upright position & remove drain plug from bottom of gearbox.
Lower deck to drain fluid.
When the fluid is drained from gearbox raise deck back up and reinsert the drain plug.
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.
DRAINPLUG
HEXHEADPLUG
GEARBOX
Page 32
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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.
2.
3.
Set all tire pressure to correct specifications (see page 23).
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 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.
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 remeasure. 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
TensionAdjustBolt
Page 33
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CARE AND MAINTENANCE
BLADETIP
DISCHARGESIDE
DECK SPINDLE BELT DIAGRAM
(Top View))
Page 34
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STANDARD SERVICE PARTS LIST
MODEL ZTR 6022:
BLADES:
Hi-Lift:
Lo-Lift(standard):
P/N 60295
P/N 60293
BELTS:
SerpentineBelt:
P/N 60194 (48")
P/N 60186 (60")
P/N 61101
Engine To Hydros:
Clutch to Driveshaft:
P/N 60187
HydrostaticTransmissionFilter:
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 6022:
22HP
Air Filter & Pre-Cleaner
Engine Oil Filter
78003
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
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TROUBLESHOOTING
1.
ENGINE WON'T TURN OVER
Mower blades engaged
--------------------------------------------------------------------------------------------------------disengage blades
----------------------------------------------------------------move steering control levers to neutral "OUT " position
-------------------------------------------------------------------------------------------------------------------------------replace fuse
Drive not in neutral
Blown fuse
Dead battery
---------------------------------------------------------------------------------------------------------------------charge or replace
-------------------------------------------------------------------------------------------------------------------------------consult dealer
Solenoid
Ignition switch
-------------------------------------------------------------------------------------------------------------------------consult dealer
----------------------------------------------------------------------------------------------------------------------------------consult dealer
Starter
2.
3.
ENGINE WILL TURN OVER BUT WON'T START
No gas
-------------------------------------------------------------------------------------------------refuel and/or clean or replace fuel filters
Over or under choked
Spark plug not firing
Carburetor maladjustment
----------------------------------------------------------------------------------------------------------------adjust choke
---------------------------------------------------------------------------------check spark plug/condition or reset gap
---------------------------------------------------------------------reset carburetor adjustment/consult dealer
Ignition Switch
--------------------------------------------------------------------------------------------consult dealer for carburetor service
HARD TO START ENGINE
Fuel line clogged
Faulty fuel pump
--------------------------------------------------------------------------------------------clean fuel line and check fuel filter
---------------------------------------------------------------------------------------------------------------------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
---------------------------------------------------------------------------------------------------------consult dealer
Dirty or maladjusted carburetor
------------------------------------------readjust carburetor* or consult dealer for carburetor service
4.
ENGINE STARTS BUT CUTS OUT
Water in gasoline
Clogged fuel line
-----------------------------------------drain old gasoline-replace with new gasoline and/or clean carburetor bowl
-------------------------------------------------------------------------------clean carburetor bowl and or check fuel filter
Vent in fuel cap plugged
----------------------------------------------------------------------------------------------------------------check vent
---------------------------------------------------------------------------------------------------------------------consult dealer
Faulty fuel pump
Maladjusted carburetor
------------------------------------------------------------------------------------------------------readjust carburetor
Engine dies when control levers are moved "IN"
------------------------------------------------------parking brake set -- release brake
5.
ENGINE KNOCKS
Low oil level
Ignition timing off
----------------------------------------------------------------------------------------------------------------------check and add oil
---------------------------------------------------------------------------------------------------------------------consult dealer
Fuel octane too low
Over heated engine
---------------------------------------------------------------------------drain and replace with higher octane gasoline
--------------------------------------------------------------------------------------------shut off engine and allow to cool
*See engine manual for engine adjustments
Page 36
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TROUBLESHOOTING
6.
7.
ENGINE SOMETIMES SKIPS AT HIGHER SPEED
Incorrect ignition timing
Carburetor maladjusted
----------------------------------------------------------------------------------------------------------------Consult dealer
--------------------------------------------------------------------------------------------------------Readjust carburetor
-------------------------------------------------------------------------------Check spark plug or condition and reset gap*
Faulty spark plugs
---------------------------------------------------------------------------------------Slow down on rough terrain
Bouncing off seat safety switch
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.)
8.
9.
ENGINE IDLES POORLY
Carburetor maladjustment -----------------------------------------------------------------------------------------------------------Consult dealer
Improper spark plug gap--------------------------------------------------------------------------------------------------Check and re-gap plug*
ENGINE BACKFIRES
Carburetor maladjustment ----------------------------------------------------------------------------------------------------------Consult dealer*
10. ENGINE RUNS BUT MOWER WON'T MOVE FORWARD
Drive belt broken or slipping ------------------------------------------------------------------------------------------------Re-tension or replace
Shift linkage disconnected-----------------------------------------------------------------------------------------------------------------Reconnect
Transmission shift arm disconnected---------------------------------------------------------------------------------------------------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-----------------------------------------------------------------------------------------------------------------------Consult dealer
Gear mating transmission/gearbox disconnected -------------------------------------------------------------------------------Consult dealer
Air in transmission ----------------------------------------------------------------------------------------------------------------------------Bleed air
Not enough tension on drive belt--------------------------------------------------------------------------------------------------------------Check
11. MOWER LOSES POWER/ TRANSMISSION OVERHEATS
Hydrostat transmission oil too low or too high -----------------------------------------------------------------Add Oil or drain oil as needed
Transmission damage-----------------------------------------------------------------------------------------------------------------Consult dealer
Transmission blowing oil out cap -----------------------------------------------------------------------------Overfilled or water contaminated
12. 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 manuals for engine adjustments
Page 37
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NOTES
Page 38
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OWNER
INFORMATION
DIXON INDUSTRIES, INC.
ABLOUNTInternationalInc.Co.
POBOX1569
COFFEYVILLEKS 673370945
316 251 2000
FAX3162514117
DATEPURCHASED
MOWER MODEL NUMBER
MOWERSERIALNUMBER
PURCHASEDFROM
Name
Address
DATE OIL CHANGED:
DATE ENGINE TUNED:
Page 39
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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 ZTR® are registered trademarks of Dixon Industries, Inc.
DIXON INDUSTRIES, INC.
ABLOUNTInternationalInc.Co.
POBOX1569
COFFEYVILLEKS 673370945
3162512000
6000 Series
6022
Part No. 13090-0700
Page 40
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