Dixon 4000 User Manual

IMPORTANT: READ CAREFULLY

The Dixon® ZTR* Mower is both easy and fun to operate. However,

any power mower must be operated properly to be safe.

It is not a toy or a recreational vehicle.

Before you start to use the mower: read the operator's manual carefully,

become completely familiar with the controls.

The information in this operator's manual applies to all

ZTR® 4000 Series Model Mowers.

Your Dixon dealer will gladly answer any questions.

and

Dixon®

See your dealer for warranty service, parts and repairs.

DIXON INDUSTRIES, INC.

A BLOUNT

PO BOX 1569

COFFEYVILLE KS 67337 0945

3162512000

International Inc. Co.

5/98

INDEX

SAFETY..................................................................

WARRANTY POLICY...............................................

SPECIFICATIONS....................................................

SEAT ADJUSTMENT............................................

CONTROLS.............................................................

OPERATION INSTRUCTIONS....................................

CARE AND MAINTENANCE...................................

STANDARD PARTS LIST.........................................

TROUBLESHOOTING..............................................

Pages 3 - 8
Page 9
Page 10
Page 11
Pages 12-15
Pages 16 -21
Pages 22 - 30
Page 31
Pages 32 - 34

4000 Series
Part No. 8950

Page 2

SAFETY

RIDING LAWN MOWERS, 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,

Page 3

SAFETY SYMBOLS

SAFETY

Safety Alert Symbol

When you see this symbol,

BE ALERT to the potential for injury.

Follow RECOMMENdEd SAfETy PRECAUTIONS And sAfE OpERATi'NG 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 4

SAFETY

T///5 CUTTINQ MOWER is CApAblE of AMpUTATiNQ l-IANds & fEET, ANd THROWiNG objECTS.

FAILURE TO

GENERAL OPERATION:

• Read, understand, and follow all instructions in the manual and on the mower before

• Only allow responsible adults, who are familiar with the instructions, to operate the

obsERVE THE followiNG sAfETy i

SERIOUS INJURY OR D

NSTRUCTIONS

EATh.

could

RESULT IN

starting.

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
the area.

• Never carry passengers.

enters

• 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
mower without either the entire grass catcher or the deflector in place.

• Slow down before turning.

operate the

• 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.

ride the mower when loading & unloading.

Do not

WARNING:

. California to cause cancer, birth defects or other reproductive harm.

The Engine Exhaust from this product contains chemicals known to the state of

Page 5

SLOPE OPERATION:

Slopes ARE A MAJOR FACTOR Related TO loSS-of'-CONTROl ANd Tlp-OVER ACCidENTS,

If you

DO

Mow across the slope with your Dixon ZTR - never up or down.

Remove obstacles such as rocks, tree limbs, etc.

CANNOT

bAck up

SAFETY

which CAN RESult IN SEVERE iNJURy OR dEATh

All slopES REQUIRE EXTRA CAUTlON.

THE

slopE

OR

if you

FEEL

uNEAsy

ON IT,

do

NOT MOW IT

.

Watch for holes, ruts or bumps. Uneven terrain could overturn the mower. Tall grass can
obstacles.

Use slow speed.

Use extra care with grass catchers or other attachments. These can change the stability of
mower.

hide

the

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.

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 6

CHILDREN:

SAFETY

TRAGIC ACCIDENTS CAN OCCUR

ChildREN ARE ATTRACTEd TO lawN MOWERS ANd

NEVER

ASSUME

if

THE OPERATOR

childREN.

childREN will

BE ALERT TO AVOid ACCidENTS.

STAY WHERE

is

NOT ALERT TO THE PRESENCE

THE

MOWiNg ACTiviTy.

ThEy

WERE LAST SEEN.

of

• 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
obscure vision.

may

Page 7

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
refueling. Do not smoke.

Never refuel the mower indoors.

Never store the mower or fuel container inside a building where there is an
flame.

• Never run a mower inside a closed area. . • "

before

open

• Keep nuts and bolts, especially blade attachment bolts, tight 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,
restarting.

• Never make adjustments or repairs with the engine running.

• Grass catcher components are subject to wear, damage, and deterioration, which

before

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 blades] or wear gloves, and use
caution when servicing them.

extra

• 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

Before disconnecting the negative [-] ground cable, make sure all switches are

battery.

OFF.

• Check to assure that the drive chains are properly adjusted. A loose chain may come off
causing loss of control. This statement applies to chain drive Models

2301, 3000 & 4000

Series.

Page 8

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: 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 90days 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.

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-__________

___________________________________________________ _____________________________________________
(Owner's Name) (Dealership)

__________________________________________________ ______________________________________________
(Address) (Address)

__________________________________________________ _____________________________________________

__________________________________________________ ______________________________________________
(Owner's Signature) (Dealer’s Signature)

SPECIFICATIONS

Models ZTR 4423 & ZTR 4424

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 8 position lift handle.

BLADE DRIVE: Electric clutch.

TRANSMISSION: Each rear wheel is independently driven by chain and sprockets through a

mechanical friction drive.

ENGINE:

Model 4423: 15HP Vanguard Briggs & Stratton, 4-Cycle, Single Cylinder, Overhead

Valve, Air-Cooled, Gasoline, Vertical Shaft With Cast Iron Cylinder
Sleeve, Oil Pump With Integral Oil Filter.

Model 4424: 15HP Kohler Command 15, 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.

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 Ibs.

CAPACITIES: Fuel 2.7 gallons total.

Rear 8-14 Ibs.

Engine Briggs &. Stratton -1.50 quarts oil.

Kohler - 2 quarts oil with filter.

DIMENSIONS: Width 47" outside rear wheel measurement.

Height 42" to top edge of seat.
Length 72" hitch tab to front bumper.

Weight 520 Ibs.

NOTE: Additional information provided in service instructions under the individual component.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

Page 10

SEAT ADJUSTMENT INSTRUCTIONS

Models ZTR 4423 & ZTR 4424

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.
tighten nuts, P/N 3205.

DO NOT

OPERATE MOWER WITHOUT SEAT

AdjusTMENTS pRopERly TiqhTENEd.

4 Raise and push seat assembly and upper body rearward to closed position.

Re-

Page 11

Page 12

CONTROLS

All CONTROLS ARE dESCRibEd fROM OPERATORS POSITION:

PARKING BRAKE:

The parking brake used on the 4000 Series Models is designed
to hold the mower from moving and is not intended for use in
stopping the mower while it is in motion.

TO SET PARKING BRAKE:

The hand operated parking brake is located on the right
of Models ZTR 4423 and ZTR 4424.

fender

To engage brake, pull lever up and to the rear.

To release brake, move lever forward and 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

light.

very

A minimum of 1/2 hour should be spent simply
driving the mower without the blade drive engaged.

Page 13

TO GO FORWARD:

From neutral position, gently push both drive levers forward.

increase speed, move levers farther forward.

TO GO BACKWARD:

From neutral position, gently pull both drive levers toward you.

CONTROLS

To

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. Park only on level surfaces.

TWIN FUNCTION THROTTLE CONTROL LEVER:

Located on control panel to operators right.

Throttle control for engine speed. Choking 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 14

BLADE DRIVE:

Located on control panel, on operator's right.

To engage the mower blades, move switch to
rear and lift.

To disengage blades, move switch backward.
Switch is clearly marked "on and off".

CIRCUIT BREAKER:

Protection of the electrical system is by
[1)15 amp circuit breaker.

CONTROLS

the

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 of operator.

Controls the cutting height.

Seven

positions of adjustment. Move lever in and

forward to lower.

Move lever in and back to raise.

Always use high for transport.

NOTE:

Page 15

OPERATION INSTRUCTIONS

The safe and successful operation of the 4000 Series Models 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
functions.

their

During initial operation, "learning to drive", set throttle at slow speed.

Sound judgement by the owner will prevent accidents.

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
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.

B. Know how to stop engine, [Turn key to off position]

in the

PAGE 16

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:

If Any Safety Check FAILS: Do Not Operate The Mower until the
been checked and repaired by an Authorized Dixon ZTR

a] In a SAFE AREA away from bystanders,

engine
b] Engage blade drive switch
c] Raise weight slightly off seat

start the

ENGINE SHOULD STOP

system has

Dealer

Page 17

THE

OPERATION INSTRUCTIONS

DIXON

ZTR

REQUIRES

ONLY

TURNING, SPEED AND DIRECTION.

TWO

DRIVE

LEVERS TO CONTROL

BRAKING,

On initial operation, set throttle speed on slow and 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.

CAUTION

engine.

STARTING INSTRUCTIONS:

1. Parking brake must be on, and blade drive
disengaged.

Engage parking brake before starting

2. Move throttle control to "Choke" position if engine
cold, full throttle if warm.

3. Insert ignition key and turn to "Start" position.

When engine starts, release ignition key. Key will
to "Run" position.

4. Move throttle from "Choke" to desired speed

5. Release parking brake.

NOTE: While mowing, "blade[s] engaged", throttle

control should be set to the MAXIMUM or wide
setting to insure adequate cooling of the engine and to
maintain mower deck blade

Engine cannot be restarted when blade drive is engaged
or the parking brake is off.

Safety switches stop engine when operator leaves seat
while mower blade is engaged.

speed.

is

return

position.

open

Always turn engine off when leaving mower.

rely on safety switches.

Page 18

DO NOT

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

grass will result in the deck plugging and cause the engine to stall.

more

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
under wet grass conditions.

5. Maintain Sharp Blades Throughout The Cutting Season. This is very important.

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
the underside of the pan, the baffles and deflectors after each use.

poor

Optimal

from

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 19

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
will greatly assist in bagging of the clippings.

dirt

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

attachment.

catching

• 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

grass catcher components.

• Keep all attachment bolts tight.

• Do Not operate the mower with the grass catching attachment partially removed.

or

• 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 20

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.

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
deck and discharge area.

Be sure that deflector is properly installed on the

discharge chute.

the

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
will allow the clippings to discharge correctly.

and dirt

5. Maintain Sharp Blades Throughout The Cutting Season.

GRASS HEIGHT SUGGESTIONS:

Correct mowing height can reduce weeds and disease by 5O to 8O %

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
heights. If in doubt, consult your local lawn professional for assistance.

Grass Types: Best Cut Heights

different cut

Zoysia 2" - 2 1/2"
Blue Grass 1 1/2"- 3"

Fescue Blends 1 1/2"- 3"
St. Augustine [Mid South] 11/2"- 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"

Page 21

;

CARE AND MAINTENANCE

This portion of the 4000 Series Models 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 on all the components used on the
4000 Series Models, a regular and thorough maintenance schedul e 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
each mower.

BATTERY: Check the fluid in the battery at frequent intervals.

Keep fluid level above the plates in each cell, using distilled water.

SEASON BATTERY STORAGE:

manufacturer, supplied with

OFF-

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 22

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. Tighten blade nut securely. Refer to diagram.

CAUTION

Wear heavy, thick gloves when holding onto cutter blade,

avoid the sharp edge of the blade.

Page 23

CARE AND MAINTENANCE

BELT TENSION:

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
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
the idler system. This is normal and not a sign of failure.

P/N 7725

of

by

MOWER DECK SERPENTINE BELT: P/N 6109

Refer to illustration for adjustment procedure.

Page 24

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 Ibs .

Rear: B -14 Ibs

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
mower. Retain this measurement. Move to the opposite side and check to see if that
is the same. If adjustment is required, turn nut on one or both of the rear
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
blades. Rear of blade tips should be level to 1 /4" higher that the front of blade
necessary, turn nut on front L-rod.

the

measurement

L-rods until both

rear of the

tips. If adjustment is

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
involved.

conditions

Page 25

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
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
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.
procedure to reinstall deck assembly].

CARE AND MAINTENANCE

[Reverse

electric

L-rods

NOTE: When deck is reinstalled on frame, check that belt is

correctly routed in the groves of all pulleys and that belt idler
applying tension to the back side of the belt.

is

Page 26

CARE AND MAINTENANCE

A CAUTION

CHANGING THE ENGINE OIL:

1. The "snap lock" oil drain valve is located

2. Place a suitable container under the drain

3. Push the valve body in and twist to clear

HOT oil may cause burns. Allow engine to cool before

draining oil.

the left side of the engine crankcase
4423, and the right side of the

valve. The fitting of a short piece of hose to
the valve will help direct the

detent notch.

oil.

4424.

on

on the

the

4. Puffing the valve body outward will start
flow of oil.

NOTE: Refer to engine manufacturers

the

recommendations for frequency of oil
changes.

OIL FILTERS:

• Oil changes on Models ZTR 4423 and ZTR 4424 require replacement of the oil

• These filters can be obtained from your authorized engine dealer.

filters.

• The use of any other oil filter may cause damage to the engine.

Model ZTR 4423 Model ZTR 4424
Briggs & Stratton Oil Filter: Kohler Oil Filter:
P/N 492 932 P/N 52 050 02

PLEASE DISPOSE OF USED OILS A T PROPER COLLECTION CENTERS.

PROTECT YOUR ENVIRONMENT

Page 27

CARE AND MAINTENANCE

OIL FILL:

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.

LUBRICATION:

CHASSIS:

LOCATIONS:

SERVICE

INTERVALS:

RECOMMENDED GREASE:

Number of grease zerks used: [4]

[1] each front wheel caster and each front wheel hub.

Every 50 hours of operation

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.

PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS.

PROTECT YOUR ENVIRONMENT

Page 28

CARE AND MAINTENANCE

DRIVE SYSTEM ADJUSTMENTS:

Due to both the complex nature of the transmission and the number of special tools required
service, adjustments should be entrusted to your dealer.

There are a number of simple owner service items which greatly influence the performance
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.

for

of the

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
preventative.

rust

Page 29

CARE AND MAINTENANCE

WHEELS AND TIRES: Correct tire pressure is important for correct operation of

mower.

Front Tires 11 X 4.00 X 5 Air Pressure 16-21 Ibs.
Rear Tires 18 X 9.50X8 Air Pressure 8-14 Ibs.

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.

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 82BB].

PARTS/SERVICE: See your Dixon dealer for replacement parts, warranty or service.

PLEASE HELP PROTECT THE ENVIRONMENT BY A VOIDING ALL

CHEMICALS WHICH MA Y DAMAGE OR CAUSE HARM TO PLANTS AND

ANIMALS IN YOUR AREA.

Page 30

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
for engine oil changes and air filter maintenance.

Protect your engine investment, use only original equipment filters.

intervals

Model ZTR 4423 15HP Precleaner Foam Element P/N 272 403

Air Filter Cartridge: P/N 493 909

Engine Oil Filter: 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.

Model ZTR 4424: 15HP Air Filter Cartridge: P/N 12 08 310

Pre-Cleaner: P/N 12 08 312
Engine 00 Filter: P/N 52 050 02

Page 31

MOWER CUT QUALITY:

TROUBLESHOOTING

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
that interact creating differences in cut quality. Examination of one or more of the
generally produce a quality cut.

The Troubleshooting Chart suggests practices and adjustments that may be helpful in
cut quality. Your Dixon ZTR dealer is also available to provide assistance to you.

SITUATION

Poor cut quality

CAUSES

Ground speed

REMEDY

Reduce mowing speed

Poor cut quality Incorrect engine to Refer to pages 23

variables

above will

improving

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

Poor cut quality Uneven tire pressures Check and adjust as required per

operators manual

Page 32

DRIVE SYSTEM:

SITUATION

Mower pulls to one
side or the other

Poor driving
performance

TROUBLESHOOTING

CAUSES

Drive adjustment

Operation of mower Review operators section

REMEDY

Consult your dealer for repair

of owners manual

turn engine over

disengaged

ELECTRICAL SYSTEM:

SITUATION

Starter will not

Starter will not
turn engine over

Battery discharge

TROUBLESHOOTING

CAUSES

Circuit breaker

Dead battery

Poor connections on
battery
Battery water low
Wrong battery installed
in mower

REMEDY

Push button to reset Consult
your dealer for repair

Charge battery

Tighten or replace as required

Battery discharge

Battery discharge

Engine electrical system Have electrical system checked by
functioning correctly your dealer

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

not

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 34

OWNER
INFORMATION

DATE PURCHASED

MOWER MODEL NUMBER_______

MOWER SERIAL NUMBER DM-

PURCHASED FROM ________________________________

Name

Address

DIXON INDUSTRIES, INC.

A BLOUNT

PO BOX 1569

COFFEYVILLE KS 67337 0945
316251 2000
FAX [phone]

International Inc. Co.

DATE OIL CHANGED:

DATE ENGINE TUNED:

4000 Series

5/98

WA R NING The Engine Exhaust from this product contains chemicals known to the State of

California to cause cancer, birth defects or other reproductive harm.

® Dixon and ZTR are registered trademarks of Dixon Industries, Inc.

DIXON INDUSTRIES, INC,

A BLOUNT

PO BOX 1569
COFFEYVlLLE KS 67337 0945
316 251 2000

International Inc. Co.

Part No. 8950