Dixon 1856 0599 Users Manual OM, ZTR 4000 SERIES, 4423, 2000, ZERO TURN

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2000 Operator's Manual
4000
SERIES
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 in this operator's manual applies to all
Dixon® ZTR® 4000 Series Model Mowers.
Your Dixon dealer will gladly answer any questions.
DIXON INDUSTRIES, INC.
A BLOUNT International Inc. Co.
PO BOX 1569
COFFEYVILLE KS 67337 0945
316 251 2000
IMPORTANT: READ CAREFULLY
See your dealer for warranty service, parts and repairs.
Page 3
INDEX
SAFETY ............................................................Pages 2 - 7
WARRANTY POLICY......................................Page 8
SPECIFICATIONS ...........................................Page 9
SEAT ADJUSTMENT ......................................Page 10
CONTROLS .....................................................Pages 11 - 14
OPERATION INSTRUCTIONS .....................Pages 15 - 20
CARE AND MAINTENANCE.........................Pages 21 - 29
STANDARD PARTS LIST................................Page 30
TROUBLESHOOTING...................................Pages 31 - 33
4000 Series
Part No. 1856-0599
Page 4
RIDING LAWNMOWERS, IF IMPROPERLY 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.
SAFETY
BLADE CONTACT
RUN-OVER BACK-OVER
TIP-OVER
Page 5
SAFETY SYMBOLS
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.
SAFETY
Safety Alert Symbol
When you see this symbol,
BE ALERT to the potential for injury.
Follow recommended safety precautions and safe
operating practices.
Danger
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.
Page 6
SAFETY
This cutting mower is capable of amputating hands & feet, and throwing objects.
Failure to observe the following safety instructions could result in
serious injury or death.
WARNING:The engine exhaust from this product contains chemicals known to the
State of California to cause cancer, birth defects or other reproductive harm.
GENERAL OPERATION:
• Read, understand, and follow all instructions in the manual and on the mower before starting.
• Only allow responsible adults, who are familiar with the instructions, to operate the mower.
• Clear the area of objects such as rocks, toys, wire, etc., which could be picked up and thrown by the blade.
• Be sure the area is clear of other people before mowing. Stop mower if anyone enters the area.
• Never carry passengers.
• Do not mow in reverse unless absolutely necessary. Always look down and behind before and while backing.
• Be aware of the mower discharge direction and do not point it at anyone. Do not operate the mower without either
the entire grass catcher or the deflector in place.
• Slow down before turning.
• Never leave a running mower unattended. Always turn off blades, set parking brake, stop engine, and remove key
before dismounting.
• 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 crossing roadways.
• Use extra care when loading or unloading the mower into a trailer or truck.
Do not ride the mower when loading & unloading.
• Always wear safety goggles or safty glasses with side shields when operating mower.
• Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mower-related
injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect
themselves and others from serious injury.
• Follow the manufacturer's recommendation for wheel weights or counterweights.
Page 7
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.
SAFETY
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.
Do not use grass catcher on steep slopes.
Page 8
Tragic accidents can occur if the operator is not alert to the
presence of children.
Children are attracted to lawn mowers and the mowing activity.
NEVER assume children will stay where they were last seen.
Be alert to avoid accidents.
• Keep children out of the mowing area and under the watchful care of another
responsible adult.
• Be alert and turn mower off if a child enters the area.
• Before and during backing, look behind and DOWN for small children.
• Never carry children. They may fall off and be seriously injured or interfere with
safe mower operation.
• Never allow children to operate the mower.
• Use extra care when approaching blind corners, shrubs, trees, or other objects that
may obscure vision.
SAFETY
CHILDREN:
Page 9
SERVICE: SAFETY
• Use extra care in handling gasoline and other fuels. They are flammable and vapors are explosive.
Use only an approved container.
Never remove gas cap or add fuel with the engine running. Allow engine to cool before refueling. Do not
smoke.
Never refuel the mower indoors.
Never store the mower or fuel container inside a building where there is an open flame.
Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers
on the ground away from your vehicle before filling.
When practical, remove gas-powered equipment from the truck or trailer and refuel it on the ground. If this
is not possible, then refuel such equipment on a trailer with a portable container, rather than from a gasoline
dispenser nozzle.
If a gasoline dispenser nozzle must be used, keep the nozzle in contact with the rim of the fuel tank or
container opening at all times until fueling is complete. Do not use a nozzle lock-open device.
• Never run a mower inside a closed area. The exhaust fumes are toxic.
• Keep nuts and bolts tight, especially blade attachment bolts, and keep equipment in good condition.
• Never tamper with safety devices. Check their proper operation regularly.
• Keep mower free of grass, leaves, or other debris buildup. Clean up oil or fuel spillage. Allow mower to cool
before storing.
• Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting.
• Never make adjustments or repairs with the engine running.
• Grass catcher components are subject to wear, damage, and deterioration, which could expose moving parts or
allow objects to be thrown. Frequently check components and replace with original equipment parts, when
necessary.
• Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and use extra caution when servicing
them.
• Batteries contain sulfuric acid. To prevent burns avoid contact with skin, eyes and clothing. To prevent a fire or
explosion keep sparks and open flames away from battery.
Before disconnecting the negative (-) ground cable, make sure all switches are OFF.
• Check to assure that the drive chains are properly adjusted. A loose chain may come off causing loss of control
Page 10
WARRANTY: The Dixon Protection Plus Warranty term is for a period of two (2 ) years from date of
purchase. DIXON ZTR MOWERS ARE WARRANTED AGAINST DEFECTS IN MATERIALS AND
WORKMANSHIP AND PROVIDES FOR REPLACEMENT OR REPAIR OF PARTS INCLUDING LABOR
COSTS. THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS AND LIMITATIONS:
1. Warranty applies only to original retail purchaser of new 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. Mowers or accessories used for commercial applications are warranted for 30 days from date of
purchase. Commercial application is any use other than, or in addition to, mowing at owner's primary
place of residence.
4. Battery warranty: Limited to 90 days from date of purchase.
5. Accessories Warranty (Grass Catchers, Snow Blades, Covers, etc.): Limited to 90 days from date of
purchase.
6. 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.
7. 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) Transaxle adjustments.
(c) Belts / chains / sprockets / cutting blades.
(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.
8. 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.
DIXON PROTECTION PLUS TWO YEAR LIMITED WARRANTY POLICY
This warranty policy applies to all (30"), (36"), (42") mowers purchased on or after March 1, 1990.
WARRANTY VALIDATION: At the time of sale, selling dealer must review each portion of this warranty document,
complete the information section below, secure customer's signature and send copy to Dixon Industries, Inc.
DATE OF PURCHASE________________________Model _______________S/N______________________
DM-
(Dealership)
(Address)
(Dealer's Signature)
(Owner's Name)
(Address)
(Owner's Signature)
Page 11
SPECIFICATIONS
Models ZTR 4423
CHASSIS: Twin 12 gauge side frames and 7 gauge transmission and engine base plate.
BODY: All body parts are made of high density polyethylene. Dent and corrosion
resistant. Front body contains access panel for battery service.
MOWER DECK: 13 GA stamped steel construction.
(3) blades combine for a 42" cut width.
Cut height approximately 1" to 4" via 7 position lift handle.
BLADE DRIVE: Electric clutch.
TRANSMISSION: Each rear wheel is independently driven by chain and sprockets through a
mechanical friction drive.
ENGINE: 15.5HP Vanguard Briggs & Stratton, 4-Cycle, Single Cylinder, Overhead
Valve, Air-Cooled, Gasoline, Vertical Shaft With Cast Iron Cylinder Sleeve,
Pressure Lubricated with oil filter.
STARTING SYSTEM: Electric by key switch operation with safety interlock blade drive.
TIRES: Front 11 X 4.00 X 5 ribbed tread.
Rear 18 X 9.50 X 8 Turf Trac RS
RECOMMENDED
TIRE PRESSURE: Front 16-21 lbs.
Rear 8-14 lbs.
CAPACITIES: Fuel 2.7 gallons total.
Engine 1.50 quarts oil.
DIMENSIONS: Width 47" outside rear wheel measurement.
Height 42" to top edge of seat.
Length 72" hitch tab to front bumper.
Weight 520 lbs.
NOTE: Additional information provided in service instructions under the individual
component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
Page 12
1. Place parking brake in ON position. (Pull brake lever up)
2. Raise and push seat assembly forward.
3. Loosen five nuts, P/N 3205, and slide seat forward or backward to desired position.
Retighten nuts, P/N 3205.
DO NOT operate mower without seat adjustments properly tightened.
4 Raise and push seat assembly and upper body rearward to closed position.
SEAT ADJUSTMENT
INSTRUCTIONS
Page 13
CONTROLS
Page 14
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.
TRANSMISSION 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.
TO SET PARKING BRAKE:
The hand operated parking brake is located on the right fender.
To engage brake, pull lever up(to the rear).
To release brake, move lever forward (down).
NOTE: Always set parking brake before dismounting.
Release parking brake before moving mower.
CAUTION Engage parking brake before restarting
starting engine.
The Dixon ZTR has a unique transaxle that requires only two drive levers to control
braking, turning, speed, and direction.
On initial operation, set throttle speed on slow. Operate with mower blade "OFF".
To avoid "over-controlling" the mower, use a light touch on the drive levers.
Slight movements using fingertip control is all that is necessary.
Page 15
CONTROLS
TO GO FORWARD:
From neutral position, gently push both drive levers forward.
To increase speed, move levers farther forward.
TO GO BACKWARD:
From neutral position, gently pull both drive levers toward you.
TURNING: Turning is controlled by moving one drive lever slightly forward or rearward of the other.
To turn left, move left lever rearward of the right lever.
To turn "square corners" move lever of desired direction to neutral.
To turn on mower's own axis (zero turning radius) stop and move one lever to reverse
position and the other to forward position.
BRAKING: To brake mower, move both levers in direction opposite of travel, release levers to neutral,
set parking brake.
THROTTLE CONTROL LEVER:
Located on control panel to operators right.
Throttle control for engine speed.
Choke for engine starting.
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 while mowing.
Neutral Slow Forward Fast Forward 90° Right Turn Slow Reverse
(Left turn opposite)
Page 16
CONTROLS
MOWER DECK CUT HEIGHT LIFT LEVER:
Located to the left of operator.
Controls the cutting height.
Seven positions of adjustment.
Move lever in and forward to lower.
Move lever in and back to raise.
NOTE: Always use high for transport.
CIRCUIT BREAKER:
Protection of the electrical system is by
(1) 15 amp circuit breaker.
If circuit breaker trips, push button to reset.
If this condition repeats, consult dealer for
inspection and repair.
BLADE DRIVE:
Located on control panel, on operator's right.
To engage the mower blades, pull up on the
switch.
To disengage blades, push down.
Page 17
OPERATION INSTRUCTIONS
Safe and successful operation will depend upon the operator having the correct knowledge of
all controls used on the mower and making good judgements about the terrain to be mowed.
NEVER
allow anyone to operate the mower without complete knowledge of all controls and
their functions.
During initial operation, "learning to drive", set throttle at slow speed.
Sound judgement by the operator will prevent accidents.
Drink/Cup Holder located on the left rear fender is for transport or carrying only!
Mower usage requires that both hands be free to control individual levers.
DO NOT ATTEMPT operation of mower with any type
of container or other object in either hand.
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 250 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. Be sure gas cap is in place.
6. Be sure parking brake is on.
7. Be sure mower blade drive is off.
8. Know how to stop engine. (Turn key to off position)
Page 18
OPERATION INSTRUCTIONS
PARKING BRAKE SWITCH TEST:a) Place Parking Brake in OFF position
b) Turn ignition switch to START
Engine should not turn over or attempt to start.
BLADE DRIVE SWITCH TEST: a) Place Parking Brake in ON position
b) Engage blade drive switch
c) Turn ignition switch to START
Engine should not turn over or attempt to start.
SEAT SWITCH TEST: a) In a SAFE AREA away from bystanders,
start the engine
b) Engage blade drive switch
c) Raise slightly off seat
ENGINE SHOULD STOP
TESTING OF SAFETY INTERLOCK SYSTEMS:
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 19
OPERATION INSTRUCTIONS
STARTING INSTRUCTIONS:
1. Parking brake must be on, and blade drive
disengaged.
2. Move throttle control to "Choke" position if
engine is cold, full throttle if warm.
3. Insert ignition key and turn to "Start"
position. When engine starts, release ignition
key. Key will return to "Run" position.
4. Move throttle from "Choke" to desired speed
position.
5. Release parking brake.
6. Operate the mower per the "Control"
instructions on page 13.
NOTE: While mowing, "blade(s) engaged", throttle
control must be set to the MAXIMUM or
wide open setting to insure adequate
cooling of the engine and to maintain
mower deck blade speed.
Page 20
OPERATION INSTRUCTIONS
MOWING WITH A MULCHING ATTACHMENT:
Mulching or recycling the grass clippings requires a totally different mowing approach than would be
normal when side discharging or bagging the grass. There may be instances or conditions where it is not
possible to hide all of the recycled or mulched clippings.
In order to achieve the best results, please read and follow the mulching tips listed below:
1. Set the engine speed control to the wide open or full setting.
2. Place the mower deck cut height selector in either the top or second notch. Never cut more
than 3/4" to 1" off the grass at any one time. Attempting to cut more grass will result in the
deck plugging and cause the engine to stall.
3. It may be necessary to cut the lawn twice to achieve acceptable mulching performance especially
on first cuttings or if the lawn is heavily fertilized.
4. Do Not Attempt To Cut Grass When It Is Wet. Mulching performance will be very poor under
wet grass conditions.
5. Maintain Sharp Blades Throughout The Cutting Season. This is very important. Optimal
mulching performance cannot be obtained with dull or nicked up blades.
6. Keep The Underside Of The Mower Deck Clean. Remove all grass and dirt buildup from the
underside of the pan, the baffles and deflectors after each use.
7. Alternate mower direction. This will evenly disperse the mulched grass clippings over the lawn
for even fertilization.
If the mulching quality of the mower does not seem to be satisfactory, try one or more of the
following tips:
1. Raise the height-of-cut setting on your mower.
2. It may be necessary to cut your grass more frequently.
3. Operate the mower at a slower ground speed.
4. Overlap cutting swaths instead of cutting a full swath with each pass.
5. Mow across the marginal areas a second time.
6. CUT HIGH - MOW OFTEN!
Page 21
OPERATION INSTRUCTIONS
MOWING WITH A GRASS CATCHER ATTACHMENT:
In order to achieve optimum performance when mowing with a grass catching attachment, please read
and follow the tips listed below.
1. Some applications may require installation of an optional weight box on the front of the mower to
offset cut grass weight.
2. Set engine speed control to the wide open or full setting.
3. Do Not Attempt To Cut Grass When It Is Wet. Wet grass will clog both the underside of the deck
and the attachment chutes. Empty bags often to prevent plugging.
4. If the grass is tall, place the mower deck cut height selector in the top or second notch. "Initially"
overlap cutting swaths instead of a full swath with each pass.
5. Keep The Underside Of The Mower Deck Clean. Frequent removal of dried grass and dirt will greatly
assist in bagging of the clippings.
6. Maintain Sharp Blades Throughout The Cutting Season. Some grass catching attachments require
"high-lift" blades.
7. Operate the mower at a slower ground speed than when mowing without a grass catching
attachment.
• Watch for low hanging branches or other obstacles which might hit the catcher top while turning
or backing the mower.
• Use care when backing to avoid pushing the grass bags into the frame or "hot" exhaust muffler of
the engine.
• Disengage blade and stop engine prior to clearing grass from either the discharge chute or grass
catcher components.
• Keep all attachment bolts tight.
• Do Not operate the mower with the grass catching attachment partially removed.
• Important: • Do not leave clippings in the bags while the mower is stored.
• Damp grass clippings are a fire hazard if left in the bags.
CAUTION
Page 22
OPERATION INSTRUCTIONS
SIDE DISCHARGE OF THE CLIPPINGS:
In order to achieve optimum performance when side discharging the grass clippings, please read and
follow the tips listed below.
Additional information can be found in the troubleshooting guide.
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 Blades Throughout The Cutting Season.
GRASS HEIGHT SUGGESTIONS:
Correct mowing height can reduce weeds and disease by 50 to 80%
The following grass cut heights are based on adequate moisture conditions and normal thatch buildup in
a healthy lawn. Some locations and applications may require slightly different cut heights. If in doubt,
consult your local lawn professional for assistance.
Grass Types: Best Cut Heights
Zoysia 2" - 2 1/2"
Blue Grass 1 1/2" - 3"
Fescue Blends 1 1/2" - 3"
St. Augustine (Mid South) 1 1/2" - 2"
St. Augustine (Deep South) 3" - 4"
Tifton Bermuda 1 1/2"
Centipede 1 1/2" - 2"
Common Bermuda 1 1/2" - 2"
Bahia/Argentina/Pensacola 2"
Be sure that deflector is properly installed on the discharge
chute.
CAUTION
Page 23
ENGINE: For engine operating and maintenance information, refer to the engine operating and
maintenance instructions furnished by the engine manufacturer, supplied with each
mower.
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.
CARE AND MAINTENANCE
This portion of the owners manual deals with normal service items which can be performed by the
owner. Please remember that if you are in doubt as to the correct service procedures to be followed,
these and other service situations can be handled by a Dixon ZTR dealer who is familiar with the
service of your mower.
MAINTENANCE SCHEDULE:
To insure a long and trouble free service life of all components, a regular and thorough
maintenance schedule should be followed. The following items should be checked after
the first (10) hours of operation and on a weekly basis, or each (40) hours of use:
1. Drive Chain
2. Drive system, belts and controls.
3. Mower deck belts.
4. Tire pressures.
5. Tightness of all nuts and bolts.
6. Battery fluid level.
7. Engine Oil.
Before performing any maintenance,
shut off engine, allow to cool.
CAUTION
Page 24
CUTTER BLADE MAINTENANCE:
NOTE: Observe proper blade position prior to removal.
1. Safely raise front of mower.
2. Hold or block blade from turning.
3. Loosen blade nut and remove blade.
4. When replacing blade, tighten blade nut securely. Refer to diagram.
CAUTION
CARE AND MAINTENANCE
Wear heavy, thick gloves when holding onto cutter blade.
Avoid touching the sharp edge of the blade.
NOTE: BE SURE BLADE IS CENTERED ON PILOT BEFORE
TIGHTENING NUT TO 60 FT. LBS. TORQUE.
Threaded end of Blade Shaft
Trash Guard
Mower Blade
Nut
Page 25
CARE AND MAINTENANCE
BELT TENSION
TRANSAXLE DRIVE BELT: P/N 7650
No adjustment required.
ENGINE TO MOWER DECK BELT: P/N 7725
No adjustment required.
Correct belt tension is maintained through a fixed engine location and a
spring loaded idler system.
A pulsing movement of the belt idler will be observed both during engagement
of the electric blade clutch and actual operation of the mower deck.
NOTE: Engagement of the electric blade clutch switch may produce a sharp
high pitched chirp or squeal as the belt tension loading is absorbed
by the idler system. This is normal and not a sign of failure.
MOWER DECK SERPENTINE BELT: P/N 6109
Refer to illustration for adjustment procedure.
Idler Weldment
"L" Rod Idler Shock Mount Hex
Nut
3
4
Tighten or Loosen
Hex Nut to achieve
this Dimension
Page 26
CARE AND MAINTENANCE
MOWER DECK LEVELING PROCEDURE:
1. Place mower on a smooth, level surface and check tire pressures to insure correct stance. Tires
should be inflated as follows: Front: 16 - 21 lbs
Rear: 8 - 14 lbs
2. Turn each outer blade tip to align with the deck in a side to side manner.
3. Measure from the floor surface up to the bottom of the blade tip on the discharge side of the
mower. Retain this measurement. Move to the opposite side and check to see if that measurement
is the same. If adjustment is required, turn nut on one or both of the rear L-rods until both
measurements are equal.
4. Turn each outer blade tip to align with the deck in a front to rear manner.
5. Measure from the floor surface up to the bottom of the blade tips at both the front and rear of the
blades. Rear of blade tips should be 1/8" to 3/8" higher that the front of blade tips. If
adjustment is necessary, turn nut on front L-rod.
NOTE: This will place the mower deck in a base measurement position. Additional adjustment may
be required to achieve desired cut for the type of grass or conditions involved.
Page 27
DECK REMOVAL:
1. Place cut height lever in lowest cut position.
2. Pull belt idler back to allow belt to be removed from idler pulley and electric clutch
pulley.
3. Remove hair pin cotter and washer from one end of deck support cross shaft.
Note location of remaining shim washers used between chassis and mower deck
plates. Slide shaft from chassis and mower deck.
4. Remove hair pin cotter and washer from each deck L-rod. Remove L-rods from
lift arms. At this point, deck will drop down.
5. Carefully raise and support front of chassis.
Slide mower deck to either side for removal.
(Reverse procedure to reinstall deck assembly).
NOTE: When deck is reinstalled on frame, check that belt is correctly routed in
the groves of all pulleys and that belt idler is applying tension to the
back side of the belt.
CARE AND MAINTENANCE
Page 28
CARE AND MAINTENANCE
CAUTION
HOT oil may cause burns. Allow engine to cool before draining oil.
CHANGING THE ENGINE OIL:
1. The "snap lock" oil drain valve is
located on the left side of the engine
crankcase.
2. Place a suitable container under the
drain valve. The fitting of a short piece
of hose to the valve will help direct the
oil.
3. Push the valve body in and twist to clear
the detent notch.
4. Pulling the valve body outward will
start the flow of oil.
NOTE: Refer to engine manufacturers
recommendations for frequency of oil
changes.
•Replace filter each time the oil is changed.
•These filters can be obtained from your authorized Briggs & Stratton engine
dealer (P/N 492 932).
•The use of any other oil filter may cause damage to the engine.
PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS.
PROTECT YOUR ENVIRONMENT
OIL FILTERS:
Page 29
1. Push the valve body in and twist into the detent notch.
2. Clean any spilled oil from engine and chassis.
3. Refill engine with type, and quantity of oil recommended by the engine manufacturer in engine
literature.
PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS.
PROTECT YOUR ENVIRONMENT
CARE AND MAINTENANCE
CHASSIS: Number of grease zerks used: (7)
LOCATIONS: (1) each front wheel caster and each front wheel hub.
(1) each mower deck
SERVICE INTERVALS: Every 50 hours of operation
RECOMMENDED GREASE: Name brand wheel bearing or multi-purpose grease
Lubricate each front wheel to allow even distribution of grease
within the wheel, rotate or spin each front wheel after (3) pumps
of the grease gun. Repeat process until the appearance of grease is
noted completely around each caster axle.
Lubrication of the mower deck hubs will help dispel moisture
within the hub casting. Bearings are of a sealed variety.
OIL FILL:
OpenClosed
LUBRICATION:
Page 30
DRIVE SYSTEM ADJUSTMENTS:
Due to both the complex nature of the transmission and the number of special tools
required for service, adjustments should be entrusted to your dealer.
There are a number of simple owner service items which greatly influence the performance
of the drive system.
1. Front and rear tires must be inflated to proper specifications.
2. Rear drive chain tension.
3. Tightness of all controls and linkages pertaining to the drive levers.
4. Lubrication of both primary and final drive chains.
(The use of a high quality chain lubricant is highly recommended.)
Proper tension for the rear drive chains is accomplished through the use of an
"automatic" adjuster located at mid-point of each rear chain.
Maintenance:
Periodically remove any build up of grass,
mud or other debris from both the spring
loaded roller and the upper guide rod.
The use of a penetrating lubricant on the
springs and rod is recommended as a rust
preventative.
CARE AND MAINTENANCE
REAR CHAIN ADJUSTMENT:
Page 31
CARE AND MAINTENANCE
WHEELS AND TIRES:
Correct tire pressure is important for correct operation of mower.
Front Tires 11 X 4.00 X 5 16-21 lbs. PSI
Rear Tires 18 X 9.50 X 8 8-14
lbs. PSI
NOTE: Check lug nuts periodically for tightness.
ELECTRICAL SYSTEMS: Keep all connections clean and tight.
CLEANING THE MOWER:Wash mower periodically. Clean above and below deck.
NOTE: Allow mower to cool before washing. If bearings are hot, they will
draw moisture inside as they dry and cause corrosion.
MOWER DECK PLATES: Check periodically. Replace bolted-on wear plates before shaft wears into
mower deck plates. See illustration.
SERIAL NUMBERS: The serial number is located on frame at rear of engine, it will begin
with DM.
WARRANTY: Refer to Warranty Registration Form (P/N 8288).
PARTS/SERVICE: See your Dixon dealer for replacement parts, warranty or service.
PLEASE HELP PROTECT THE ENVIRONMENT BY AVOIDING ALL
CHEMICALS WHICH MAY DAMAGE OR CAUSE HARM TO PLANTS AND
ANIMALS IN YOUR AREA.
Page 32
STANDARD SERVICE PARTS LIST
BLADES: Lo-Lift: P/N 6236
Standard Hi-Lift: P/N 8688
BELTS: Engine To Mower Deck: P/N 7725
Serpentine Belt: P/N 6109
Engine To Transmission:P/N 2497
BRIGGS & STRATTON FILTER PART NUMBERS:
Please refer to Briggs & Stratton Engine Operators Manual for correct service intervals
for engine oil changes and air filter maintenance.
Protect your engine investment, use only original equipment filters.
Precleaner Foam Element: P/N 272 403
Air Filter Cartridge: P/N 493 909
Engine Oil Filter: P/N 492 932
Page 33
SITUATION CAUSES REMEDY
Poor cut quality Ground speed too fast Reduce mowing speed
Poor cut quality Incorrect engine to Install correct belt P/N 7725
mower deck belt
Poor cut quality Engine RPM too low Increase engine RPM to maximum
Poor cut quality Dull or bent blade Sharpen or replace as required
Poor cut quality Un-level mower deck Refer to page 24
Poor cut quality Grass buildup under Clean out underside of mower deck
mower deck
Poor cut quality Improper blades Replace with original equipment
blade designed for the 4000 Series
Models Refer to page 30
Poor cut quality Uneven tire pressures Check and adjust as required per
operators manual
MOWER CUT QUALITY:
There are many variables that can effect the cut quality of any riding mower. Type and conditions of grass,
cut height setting, engine RPM and ground speed are some of the variables that interact creating
differences in cut quality. Examination of one or more of the above will generally produce a quality cut.
The Troubleshooting Chart suggests practices and adjustments that may be helpful in improving cut
quality. Your Dixon ZTR dealer is also available to provide assistance to you.
TROUBLESHOOTING
Page 34
SITUATION CAUSES REMEDY
Mower pulls to one Drive adjustment Consult your dealer for repair
side or the other
Poor driving Operation of mower Review operators section
performance of owners manual
DRIVE SYSTEM:
TROUBLESHOOTING
Page 35
ELECTRICAL SYSTEM:
SITUATION CAUSES REMEDY
Starter will not Circuit breaker Push button to reset
turn engine over disengaged Consult your dealer for repair
Starter will not Dead battery Charge battery
turn engine over
Battery discharge Poor connections on Tighten or replace as required
battery
Battery water low
Wrong battery installed
in mower
Battery discharge Engine electrical system Have electrical system checked by
not functioning correctly your dealer
Battery discharge Engine being operated Increase engine RPM
at too low an RPM Contact your dealer for
information
NOTE: Electrical system failures are generally simple in nature, always check the obvious first and then
move onto the more complicated parts used. Poor battery service, loose connections,
corrosion, frayed or broken wiring, are more likely than component failure.
TROUBLESHOOTING
Page 36
NOTES
DATE PURCHASED
MOWER MODEL NUMBER
MOWER SERIAL NUMBER
PURCHASED FROM
OWNER
INFORMATION
DATE OIL CHANGED: DATE ENGINE TUNED:
DM-
Address
Name
DIXON INDUSTRIES, INC.
A BLOUNT International Inc. Co.
PO BOX 1569
COFFEYVILLE KS 67337 0945
316 251 2000
FAX 316 251 4117
Dixon® and ZTR® are registered trademarks of Dixon Industries, Inc.
4000Series
4423
Part No. 1856-0599
DIXON INDUSTRIES, INC.
A BLOUNT International Inc. Co.
PO BOX 1569
COFFEYVILLE KS 67337 0945
316 251 2000
The engine exhaust from this product contains chemicals known to the
State of
California to cause cancer, birth defects or other reproductive harm.
WARNING:

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