1999 Operator's Manual
4000
SERIES
INDEX
SAFETY.................................................................Pages 2 - 7
WARRANTY POLICY............................................Page
SPECIFICATIONS .................................................Page
SEAT ADJUSTMENT............................................Page
8
9
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. 8950-598
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
RUN-OVER
BACK-OVER
...read and understand this manual to prevent injuries.
Page 4
SAFETY
SAFETY SYMBOLS
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.
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
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.
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.
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
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.
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 7
SAFETY
CHILDREN:
Tragic accidents can occur if the operator is not alert to the
presence of children.
Children are attracted to lawn mowers and the mowing activity.
NEVER assume children will stay where they were last seen.
Be alert to avoid accidents.
• Keep children out of the mowing area and under the watchful care of another
responsible adult.
• Be alert and turn mower off if a child enters the area.
• Before and during backing, look behind and DOWN for small children.
• Never carry children. They may fall off and be seriously injured or interfere with safe
mower operation.
• Never allow children to operate the mower.
• Use extra care when approaching blind corners, shrubs, trees, or other objects that
may obscure vision.
Page 8
SAFETY
SERVICE:
•
Use extra care in handling gasoline and other fuels. They are flammable and vapors
are explosive.
Use only an approved container.
Never remove 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 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 9
DIXON PROTECTION PLUS TWO YEAR LIMITED WARRANTY POLICY
Thiswarrantypolicyappliestoall(30"),(36"),(42")mowerspurchasedonorafterMarch1,1990.
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.
2.
Warranty applies only to original retail purchaser of new and unused mowers and accessories.
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.
5.
Battery warranty: Limited to 90 days from date of purchase.
Accessories Warranty (Grass Catchers, Snow Blades, Covers, etc.): Limited to 90 days from date of
purchase.
6.
7.
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.
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.
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.
DM-
DATEOFPURCHASE________________________Model_______________S/N______________________
(Owner'sName)
(Address)
(Dealership)
(Address)
(Owner'sSignature)
(Dealer'sSignature)
Page 10
SPECIFICATIONS
Models ZTR 4423 & ZTR 4426
CHASSIS:
BODY:
Twin 12 gauge side frames and 7 gauge transmission and engine base plate.
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.
BLADEDRIVE:
TRANSMISSION:
ENGINE:
Electric clutch.
Each rear wheel is independently driven by chain and sprockets through a
mechanical friction drive.
Model 4423:
15HP Vanguard Briggs & Stratton, 4-Cycle, Single Cylinder, Overhead
Valve, Air-Cooled, Gasoline, Vertical Shaft With Cast Iron Cylinder Sleeve,
Pressure Lubricated with oil filter.
Model 4426:
16HP Kohler Command 16, 4-Cycle, Single Cylinder, Overhead Valve, Air-
Cooled, Gasoline, Pressure Lubricated, With Oil Filter, Vertical Shaft,
Aluminum Head and Block with Cast-Iron Cylinder Liner.
STARTINGSYSTEM:
TIRES:
Electric by key switch operation with safety interlock blade drive.
Front
Rear
11 X 4.00 X 5 ribbed tread.
18 X 9.50 X 8 Turf Trac RS
RECOMMENDED
TIREPRESSURE:
Front
Rear
16-21 lbs.
8-14 lbs.
CAPACITIES:
DIMENSIONS:
Fuel
2.7 gallons total.
Briggs & Stratton - 1.50 quarts oil.
Kohler - 2 quarts oil with filter.
Engine
Width
47" outside rear wheel measurement.
42" to top edge of seat.
72" hitch tab to front bumper.
520 lbs.
Height
Length
Weight
NOTE:
Additionalinformationprovidedinserviceinstructionsundertheindividualcomponent.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
Page 11
SEAT ADJUSTMENT INSTRUCTIONS
1.
2.
3.
Place parking brake in ON position. (Pull brake lever up)
Raise and push seat assembly forward.
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.
Page 12
CONTROLS
Page 13
CONTROLS
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.
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.
CAUTION
Engage parking brake before
starting engine.
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.
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.
Page 14
CONTROLS
Neutral
Slow Forward
Fast Forward
90° Right Turn
(Left turn opposite)
Slow Reverse
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.
Page 15
CONTROLS
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.
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.
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.
Page 16
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 17
OPERATION INSTRUCTIONS
TESTING OF SAFETY INTERLOCK SYSTEMS:
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
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
OPERATION INSTRUCTIONS
STARTING INSTRUCTIONS:
1.
2.
3.
Parking brake must be on, and blade drive
disengaged.
Move throttle control to "Choke" position if engine is
cold, full throttle if warm.
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.
6.
Release parking brake.
Operate the mower per the "Control" instructions on
page 12.
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 19
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 20
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. MaintainSharpBladesThroughoutTheCuttingSeason. Somegrasscatchingattachments
require "high-lift" blades.
7. Operate the mower at a slower ground speed than when mowing without a grass catching
attachment.
CAUTION
• 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.
Page 21
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.
Be sure that deflector is properly installed on thedischarge 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 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"
1 1/2" - 3"
1 1/2" - 3"
1 1/2" - 2"
3" - 4"
Blue Grass
Fescue Blends
St. Augustine (Mid South)
St. Augustine (Deep South)
Tifton Bermuda
1 1/2"
Centipede
Common Bermuda
Bahia/Argentina/Pensacola
1 1/2" - 2"
1 1/2" - 2"
2"
Page 22
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.
CAUTION
Before performing any maintenance,
shut off engine, allow to cool.
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.
Page 23
CARE AND MAINTENANCE
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.
Wearheavy, thickgloveswhenholdingontocutterblade.
Avoid touching the sharp edge of the blade.
CAUTION
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 24
CARE AND MAINTENANCE
BELT TENSION
TRANSAXLE DRIVE BELT:
No adjustment required.
P/N 7650
P/N 7725
ENGINE TO MOWER DECK BELT:
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
Idler Shock Mount
"L" Rod
Hex
Nut
3
4
Tighten or Loosen
Hex Nut to achieve
this Dimension
Page 25
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 26
CARE AND MAINTENANCE
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.
Page 27
CARE AND MAINTENANCE
CAUTION
HOToilmaycauseburns. Allowenginetocoolbeforedraining
oil.
CHANGING THE ENGINE OIL:
1. The "snap lock" oil drain valve is located
on the left side of the engine crankcase
on the Briggs & Stratton, and the right
side of the Kohler.
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.
OIL FILTERS:
•Replace filter each time the oil is changed.
•These filters can be obtained from your authorized engine dealer.
•The use of any other oil filter may cause damage to the engine.
Briggs & Stratton Oil Filter:
P/N 492 932
Kohler Oil Filter:
P/N 52 050 02
PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS.
PROTECT YOUR ENVIRONMENT
Page 28
CARE AND MAINTENANCE
OIL FILL:
1. Push the valve body in and twist into the detent notch.
Closed
Open
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.
LUBRICATION:
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.
Lubricationofthemowerdeckhubswillhelpdispelmoisture
within the hub casting. Bearings are of a sealed variety.
PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS.
PROTECT YOUR ENVIRONMENT
Page 29
CARE AND MAINTENANCE
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.)
REAR CHAIN ADJUSTMENT:
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.
Page 30
CARE AND MAINTENANCE
WHEELS AND TIRES:
Correct tire pressure is important for correct operation of mower.
Front Tires
Rear Tires
11 X 4.00 X 5
18 X 9.50 X 8
16-21 lbs. PSI
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 dryand cause corrosion.
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 31
STANDARD SERVICE PARTS LIST
BLADES:
BELTS:
Lo-Lift:
Standard Hi-Lift:
P/N 6236
P/N 8688
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:
Air Filter Cartridge:
Engine Oil Filter:
P/N 272 403
P/N 493 909
P/N 492 932
KOHLER FILTER PART NUMBERS:
Please refer to Kohler Engine Operators Manual for correct service intervals for engine oil
changes and air filter maintenance.
Protect your engine investment, use only original equipment filters.
Air Filter Cartridge:
Pre-Cleaner:
Engine Oil Filter:
P/N 12 08 310
P/N 12 08 312
P/N 52 050 02
Page 32
TROUBLESHOOTING
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.
SITUATION
CAUSES
REMEDY
Poor cut quality
Poor cut quality
Ground speed too fast
Reduce mowing speed
Install correct belt P/N 7725
Incorrect engine to
mower deck belt
Poor cut quality
Poor cut quality
Poor cut quality
Poor cut quality
Engine RPM too low
Dull or bent blade
Un-level mower deck
Increase engine RPM to maximum
Sharpen or replace as required
Refer to page 23
Grass buildup under
mower deck
Clean out underside of mower deck
Poor cut quality
Poor cut quality
Improper blades
Replace with original equipment
blade designed for the 4000 Series
Models Refer to page 29
Uneven tire pressures
Check and adjust as required per
operators manual
Page 33
TROUBLESHOOTING
DRIVE SYSTEM:
SITUATION
CAUSES
REMEDY
Mower pulls to one
side or the other
Drive adjustment
Consult your dealer for repair
Poor driving
performance
Operation of mower
Review operators section
of owners manual
Page 34
TROUBLESHOOTING
ELECTRICAL SYSTEM:
SITUATION
CAUSES
REMEDY
Starter will not
turn engine over
Circuit breaker
disengaged
Push button to reset
Consult your dealer for repair
Starter will not
Dead battery
Charge battery
turn engine over
Battery discharge
Poor connections on
battery
Tighten or replace as required
Battery water low
Wrong battery installed
in mower
Battery discharge
Battery discharge
Engine electrical system Have electrical system checked by
not functioning correctly your dealer
Engine being operated
at too low an RPM
Increase engine 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.
Page 35
NOTES
Page 36
NOTES
P37
OWNER
INFORMATION
DIXONINDUSTRIES,INC.
A BLOUNT International Inc. Co.
PO BOX 1569
COFFEYVILLE KS 67337 0945
316 251 2000
FAX 316 251 4117
DATE PURCHASED
MOWER MODEL NUMBER
DM-
MOWER SERIAL NUMBER
PURCHASED FROM
Name
Address
DATE OIL CHANGED:
DATE ENGINE TUNED:
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.
A BLOUNT International Inc. Co.
PO BOX 1569
COFFEYVILLE KS 67337 0945
316 251 2000
4000Series
Part No. 8950-0598
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