Dixon ZTR 6000 Series User manual

ZTR®
OPERATOR’S MANUAL
6000 SERIES
FORWARD MOUNT
2002

IMPORTANT - READ CAREFULLY
The Dixon®ZTR®Mower is both easy and fun to operate.
However, any power mower must be operated properly to be
safe. It is not a toy or a recreational vehicle. Before you
start to use the mower, read the operator’s manual carefully
and become completely familiar with the controls.
The information contained in this manual applies to all
Dixon®ZTR®6000 Series Commercial Mowers. Your
Dixon dealer will gladly answer any questions.
See your dealer for warranty service, parts and repairs.

3
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

4
RIDING LAWN MOWERS,
IFIMPROPERLY OPERATED,
CAN CAUSE SERIOUS INJURY OR DEATH.
The most common causes of injury to the operator or bystander...
...read and understand this manual to prevent injuries.
BLADECONTACT
TIP OVER
RUNOVER
BACK OVER
SAFETY

5
Safety Alert Symbol
When you see this symbol,
BE ALERT to the potential for injury.
DANGER
(highlighted in red)
indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
WARNING
(highlighted in orange)
indicates a potentially
hazardous situation which, if not
avoided, could result in death or
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.
Follow recommended safety precautions
and safe operating practices.
SAFETY

6
Failure to observe the following safety
instructions could result in serious injury or death.
GENERALOPERATION:
•Read,understand,andfollowallinstructionsinthemanual
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.
•NEVERcarrypassengers.
•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. Alwaysturn off
blades, set parking brake, stop engine and remove key before
dismounting.
SAFETY

7
GENERAL OPERATION (continued) :
•Turn off blades when not mowing.
•Stop engine before removing grass catcher or unclogging
chute.
•Mow only in daylight or good artificial light.
•Do not operate the mower while under the influence of
alcohol or drugs.
•Watch for traffic when operating near or 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 manufacturer’s recommendation for wheel
weights and counterweights.
•Maintain or replace safety & instruction labels as needed.
WARNING:
The engine exhaust from this product contains chemicals known to the
State of California to cause cancer, birth defects or other reproductive
harm.
SAFETY

8
SLOPE OPERATION:
Slopes are a major factor related to loss-of-control and tip-over accidents,
which can result in severe injury or death.
All slopes require extra caution.
If you cannot back up the slope or if you feel uneasy on it,
do not mow it !
DO
•Mow across the slope with your Dixon ZTR - never up or down.
•Remove obstacles such as 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.
SAFETY

9
SAFETY
CHILDREN:
Tragic accidents can occur if the operator is
not alert to the presence of children.
Children are attracted to lawn mowers and the mowing activity.
NEVER assume children will stay where they were last seen.
Be alert to avoid accidents.
• Keep children out of the mowing area and under the
watchful care of another responsible 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.

10
SERVICE:
• Useextra care in handling gasoline and otherfuels. Theyare
flammableandvaporsareexplosive.
Useonlyanapprovedcontainer.
Neverremove fuelcapor addfuelwithengine running.
Allowenginetocoolbeforerefueling.
Donotsmoke while refueling.
Neverrefuelthemowerindoors.
Neverstore themoweror fuelcontainerinside abuilding
where there is an open flame.
Iffuelisspilledonclothing,changeclothingimmediately.
Toprevent fire andexplosioncausedby static electricity:
Neverfill containers inside a vehicle or on a truck
or trailer bed with a plastic liner. Always place
containersonthegroundawayfromyourvehicle
beforefilling.
Whenpractical,removefuel-poweredequipment
from the truck or trailer and refuel it on the
ground. If this is not possible, then refuel such
equipmentonatrailerwithaportablecontainer,
ratherthan fromafuel dispensernozzle.
If a fuel dispenser nozzle must be used, keep the
nozzle in contact with the rim of the fuel tank or
containeropeningatalltimesuntilfuelingis
complete. Do not use a nozzle lock-open device.
SAFETY

11
SERVICE(continued):
• Never run a mower inside a closed area. The exhaust fumes are
toxic.
• Keepnutsandboltstight, especially blade attachment bolts, and
keepequipmentingood condition.
• Nevertamperwithsafetydevices. Checktheirproperoperation
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,
ifnecessary,before restarting.
• Nevermakeadjustmentsorrepairswiththeenginerunning
unlessotherwisespecified.
• Grass catcher components are subject to wear, damage and
deterioration,whichcouldexposemovingpartsorallowobjects
tobethrown. Frequentlycheckcomponentsand replace with
originalequipmentparts,whennecessary.
• Mower blades are sharp and can cut. Wrap the blade(s) or wear
gloves,and useextracautionwhen servicingthem.
• Batteriescontainsulfuric acid. To preventburnsavoidcontact
with skin, eyes and clothing. To prevent a fire or explosion keep
sparks and open flames away from battery.
• Beforedisconnectingthenegative (-)groundcable,makesureall
switches are OFF.
SAFETY

12
DIXON INDUSTRIES, INC.
aBLOUNTcompany
AirportIndustrialPark
P.O.Box1569
Coffeyville,Ks67337-0945
620-251-2000
Fax [phone]
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 owner’s
primary place of residence.
DIXONZTRMOWERSAREWARRANTEDAGAINSTDEFECTSINMATERIALS
ANDWORKMANSHIPANDPROVIDESFORREPLACEMENTORREPAIROF
PARTSINCLUDINGLABORCOSTS. THISWARRANTY ISSUBJECTTOTHE
FOLLOWINGCONDITIONSANDLIMITATIONS:
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. Batterywarranty: Limitedto90 days from dateofpurchase.
4. AccessoriesWarranty (GrassCatchers,Snow Blades,Covers,etc.): Limited to90days fromdateof
purchase.
5. Warrantydoesnot apply todamageintransit or incidentsofmisuse,negligence, accidents, or
alteration. TheuseofpartsorcomponentsotherthanthosesuppliedbyDixonIndustries,Inc.VOIDS
ALLWARRANTY.
6. Thefollowingitems arenotcovered bythiswarranty policy:
a. Pick upanddelivery charges fortransportationof mowertoandfrom anauthorizedDixon
dealer’splaceofbusiness.
b. Routine maintenance oradjustments.
c. Belts/cuttingblades/hydrostaticfilters.
d. Engines - All enginesusedonDixonZTR mowers are warranted bytheindividualengine
manufacturer.
e. Anycostsor expenseofproviding substituteequipmentwhile repairworkis being
performed on a warranted mower.
7. Thereis nootherexpress warranty. Impliedwarranties,including thoseofmerchantabilityandfitness
for a particular purpose, are limited to the same duration of the express warranty, and to the extent
permittedbylaw anyandall impliedwarrantiesare excluded.Liabilitiesforconsequential damages
under any and all warranties are excluded.
Blue/Customer Yellow/Dealer White/DixonInd.
WARRANTYVALIDATION: Atthetimeofsale,sellingdealermustrevieweachportionofthiswarranty
document,completethe informationsectionbelow, securecustomer’ssignature &sendcopy toDixon
Industries, Inc.
DATE OF PURCHASE____________________MODEL___________________S/N_______________
_____________________________________ ______________________________________
Owner’s Name Dealership
_____________________________________ ______________________________________
Address Address
______________________________________ _______________________________________
_____________________________ ______________________________

13
SPECIFICATIONS
6000 Series Forward Mount
CHASSIS: Sheet metal construction frame.
BODY: Folded sheet metal. Seat lifts up for access to battery and belt service.
SEAT: Designed for operator comfort by use of high density closed cell foam
padded back and arm rests, upholstered with CorduraTM water-
repellent fabric. Seat is adjustable fore and aft.
MOWERDECK: 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”
to5” via9 positionlift handle.
BLADEDRIVE: Electric clutch.
DRIVESYSTEM: 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 KohlerCommand,4-cycle,v-configuration,overheadvalve,air
cooled,gasoline,horizontalshaft,aluminum head,andcrankcasewith
castironliners, fullpressure lubrication/fullflowfilter, pulse-typefuel
pump,fixedjet carburetorw/smart-choke,electronicignition,in-line fuel
filter,dualelement aircleaner.
STARTING SYSTEM: Electric by key switch operation with safety interlocks on parking brake
andblade driveclutch.
TIRES: Front4.10x3.50-4
Rear6.00x13.00-5
Drive10.0x10.00-20
RECOMMENDED Front 16lbs.
TIREPRESSURE: Rear 12lbs.
CAPACITIES: Fuel- 5gallons
Hydrostat oil tank - 3 quart with in-line 40 micron filter
Hydrostat oil recommendation, refer to page 29
Engine-2quartsSAE10W30 (withfilter)
DIMENSIONS: Width 57-1/2”(48”Deck) 69-1/2”(60”Deck)
Height 45-1/2”
Length 96”(48”Deck),101”(60”Deck)
Weight 960lbs.(48”Deck),1030lbs.(60”Deck)
Additional information provided in service instructions under the individual component.

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

15
CONTROLS
CONTROLLEVERS
Note: For access to the seat, move control levers to neutral position and
swing them outward.
TOGOFORWARD:
•From neutral position, gently push both control levers forward.
•To increase speed, move levers further forward.
TOGOBACKWARD:
•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 mower’s own axis (zero turning radius), stop and move one
lever to reverse position and the other to forward position.
BRAKING:
•To brake mower, move both levers in direction opposite of travel.
LEFT TURN OPPOSITE
Note: The pressure required to operate the mower is very light.

16
CONTROLS
PARKING BRAKE
The parking brake is designed to hold the
mower from moving and is not intended
for use in stopping the mower while it is
in motion.
Engage parking brake
beforestarting engine.
TO SET PARKING BRAKE
Thehand operated parking brake is located at theright
hand side of the mower.
Toengagebrake,pullrearward.
Toreleasebrake,moveleverforward.
NOTE: Alwaysset parking brake before dismounting.
Releaseparkingbrakebeforemovingmower.
HYDRO-GEAR DRIVE SYSTEM:
Allows the mower to turn on its own axis (zero turning
radius).
Each lever controls one side of the mower.
CAUTION

17
CONTROLS
MOWER BLADE SWITCH:
Located on the control panel to the operator’s right.
To engage blades: pull up on switch
To disengage blades: push down
CHOKE CONTROL LEVER:
Located on control panel to operator’s left. Use to start a cold engine.
THROTTLE CONTROL LEVER:
Located on control panel to operator’s right. Controls engine speed, slow
to maximum.
Whilemowing,throttlecontrol shouldbesettoMAXIMUMor
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 operator’s right. Protection of the
electricalsystemisby(2)30ampcircuitbreakers.
Ifcircuitbreakertrips, pushbuttontoreset.
Ifcondtionrepeats,consultdealerforinspectionandrepair.
MOWER DECK CUT HEIGHT LIFT LEVER:
Located to the right and front of the operator.
Controlsthecuttingheight.
Ninepositionsofadjustment.
Depresstrigger and movelever forward tolower deck.
Depresstriggerandpulllever 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: Alwaysusehighpositionfortransport.

18
OPERATION INSTRUCTIONS
The safe and successful operation of the 6000 Series will depend
upon the operator having the correct knowledge of all controls used
onthe mower and making goodjudgements about the terrain to be
mowed.
NEVER allow anyone to operate the mower without complete
knowledge of all controls and their functions.
Duringinitial operation,“learningto drive”,setthrottle atslowspeed.
Soundjudgement bytheoperator willpreventaccidents.
TOWING
Towingatrailer or other attachment that is too heavycoulddamge
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. Readengine manufacturer’s operatingand
maintenance instructions.
3. Check engine oil.
4. Check fuel cap to be sure it is in place.
5. Be sure parking brake is on.
6. Be sure that mower blade drive is off.
7. Know how to stop engine. (Turn key to off position).

19
INTERLOCK SWITCH TEST
Note: Operatormust be seatedin normal operatingposition to
perform these tests.
1. With engine off, turn mower blade on and attempt to
start engine.
ENGINESHOULD NOTSTART.
2. With engine off, move control levers in and attempt to
start engine.
ENGINESHOULD NOTSTART
3. In a SAFE AREA, away from bystanders, start the
engine, place throttle setting at maximum or full.
Engage the blade drive through the electric clutch
switch. Raise slightly off of seat.
ENGINE SHOULD STOP.
4. With engine running, set parking brake and move
leversinboard.
ENGINE SHOULD STOP.
If any safety check fails, do not operate the mower until the
system has been checked and repaired by an authorized
DixonZTR dealer.
OPERATIONINSTRUCTIONS

20
OPERATION INSTRUCTIONS
STARTING INSTRUCTIONS (cold engine):
1. Operator must be seated in normal operating position.
2. Set parking brake.
3. Pushchokecontrolleverfullyfoward.
4. Pushthrottlecontrolleverto1/2setting.
5. Insertignition key and turnto“start” position. When engine
starts,releaseignitionkey. Keywillreturnto“run”position.
6. Onceenginestarts to warm up, slowlymovechoke control lever to
thefullyclosedposition.
7. Movethrottlecontrolleverto the wide openormaximumsetting
for actual operation of the mower deck.
8. Engine must be operated at wide open or maximum setting to
insureadequate lubrication, cooling andcut quality of themower
deck.
Note: 6000Seriesmowerswillrequireaslightlylongerwarm-upperiod
usingpartialchokesettings.
CAUTION Do not operate the engine in an enclosed area
due to the harmful exhaust gas produced.