Dixon Lawn Mower 13090 0700 User Guide

1999 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  
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:  
25HP 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. Wlectric blade drive switch  
tumanual lever turned forward,  
pae 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.  
NOTE: The tractor should never be  
FREEWHEELLEVER  
pulled at more than 2 miles per hour or  
for any appreciable distance.  
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 6025 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 if blades 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  
(50 hours 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.  
Page 28  
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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.  
Page 30  
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CARE AND MAINTENANCE  
FOOTDECKINVERTICAL  
POSITION  
KING  
DOW
ENG
HELP  
NGER  
CKCYLINDER  
QUIC
(dec
RELEASEPIN  
uckcylinder)  
LIFTC
DLEHOLE  
NTI-BUCK  
YLINDER  
OLDER  
DECKLIFTHANDLECATCH  
Page 31  
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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 6025:  
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 6025:  
25HP  
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 6025 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 6025:  
25HP  
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  
3162512000  
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  
6000 Series  
6025  
Part No. 13090-0700  
COFFEYVILLEKS 673370945  
3162512000  
Page 40  
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