Dixon Lawn Mower 13632 0702 User Manual

ZTR®  
OPERATOR’S MANUAL  
2003  
 
INDEX  
Page  
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11  
Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . . . . . . . .14  
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-17  
Operation Instructions. . . . . . . . . . . . . . . . . . . 18-27  
Care & Maintenance. . . . . . . . . . . . . . . . . . . . . .28-39  
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 40-41  
Standard Service Parts List. . . . . . . . . . . . . . . . . . . .42  
4000 Series  
Part No. 13632-0702  
3
 
SAFETY  
RIDING LAWN MOWERS,  
IF IMPROPERLY OPERATED,  
CAN CAUSE SERIOUS INJURY OR DEATH.  
The most common causes of injury to the operator or bystander...  
BLADE CONTACT  
TIP OVER  
RUN OVER  
BACK OVER  
...read and understand this manual to prevent injuries.  
4
 
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  
(highlighted in red)  
indicates an imminently hazardous  
situation which, if not avoided, will  
result in death or serious injury.  
WARNING  
(highlighted in orange)  
indicates a potentially  
hazardous situation which, if not  
avoided, could result in death or  
serious injury.  
CAUTION  
(highlighted in yellow)  
indicates a potentially  
hazardous situation which, if not  
avoided, may result in minor or  
moderate injury. It may also be used  
to alert against unsafe practices.  
5
 
SAFETY  
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 & 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 & behind before & 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.  
6
 
SAFETY  
GENERAL OPERATION (continued):  
•Turn off blades when not mowing.  
•Stop engine before removing grass catcher or  
unclogging chute.  
•Mow only in daylight or good artificial light.  
•Do not operate the mower while under the  
influence of alcohol or drugs.  
•Watch for traffic when operating near or  
crossing roadways.  
•Use extra care when loading or unloading the  
mower into a trailer or truck. Do not ride the  
mower when loading and unloading.  
•Always wear safety goggles or safety glasses  
with side shields when operating mower.  
•Data indicates that operators, age 60 years and  
above, are involved in a large percentage of riding  
mower-related injuries. These operators should  
evaluate their ability to operate the riding mower  
safely enough to protect themselves and others  
from serious injury.  
•Follow the manufacturer’s recommendation for  
wheel weights and counterweights.  
•Maintain or replace safety & instruction labels as  
needed.  
The engine exhaust from this product contains chemicals known to the State of  
California to cause cancer, birth defects or other reproductive harm.  
WARNING:  
7
 
SAFETY  
SLOPE OPERATION:  
Slopes are a major factor related to loss-of-control and tip-over  
accidents, which can result in severe injury or death.  
All slopes require extra caution.  
If you cannot back up the slope or if you feel uneasy on it,  
do not mow it!  
DO  
Mow across the slope with your Dixon ZTR - never up or down.  
Remove obstacles such as rocks, tree limbs, etc.  
Watch for holes, ruts or bumps. Uneven terrain could overturn  
the mower. Tall grass can hide obstacles.  
Use slow speed. Tires may lose traction on slopes even though  
the brakes are functioning properly.  
Use extra care with grass catchers or other attachments. These  
can change the stability of the mower.  
Keep all movement on the slopes slow and gradual. Do not  
make sudden changes in speed or direction.  
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.  
8
 
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 seri-  
ously 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.  
9
 
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 fuel cap or add fuel with engine  
running. Allow engine to cool before refueling.  
Do not smoke while refueling.  
Never refuel the mower indoors.  
Never store the mower or fuel container inside  
a building where there is an open flame.  
If fuel is spilled on clothing, change clothing  
immediately.  
To prevent fire and explosion caused by static  
electricity:  
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 fuel-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 fuel dispenser nozzle.  
If a fuel 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.  
10  
 
SAFETY  
SERVICE (continued):  
•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 build-  
up. 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 unless otherwise specified.  
•Grass catcher components are subject to wear, damage  
and deterioration, which could expose moving parts or  
allow objects to be thrown. Frequently check compo-  
nents 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.  
11  
 
DIXON PROTECTION PLUS TWO YEAR LIMITED WARRANTY  
TRANSAXLE MODELS  
WARRANTY: Home Owner Application: Dixon Transaxle Models, used only at owner’s primary  
place of residence are warranted for a period of two (2) years from date of purchase.  
Commercial Application: defined as use other than, or in addition to, mowing at owner’s primary  
place of residence. Dixon Transaxle Models, used in commercial application are warranted for  
a period of (30) days from the 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.  
4.  
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.  
5.  
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.  
The following items are not covered by this warranty policy:  
(a) Pick up and delivery charges for transportation of mower to and from an  
Authorized Dixon Dealer's place of business.  
(b) Routine maintenance or adjustments (including transaxle adjustments)  
(c) Belts/Blades/Chains/Sprockets  
(d) Engines -- All engines used on Dixon ZTR mowers are warranted by each  
individual engine manufacturer.  
(e) Any costs or expense of providing substitute equipment while repair work is  
being performed on a warranted mower.  
7.  
There is no other express warranty. Implied warranties, including those of merchant  
ability 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.  
Copies: Pink/Customer  
Yellow/Dealer  
White/Return to Dixon Ind.  
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  
Deck Size  
S/N  
(Owner's Name)  
(Street Address)  
(City/State/Zip)  
(Dealership Name & Dealer Number)  
(Street Address)  
(City/State/Zip)  
(Owner's Signature)  
(Dealer's Signature)  
DIXON INDUSTRIES, INC.  
A BLOUNT International Inc. Co.  
PO BOX 1569  
COFFEYVILLE KS 67337 0945  
PHONE 620 251 2000  
1-877-CUT-MORE  
FAX 620 251 4117  
12  
 
SPECIFICATIONS  
Model ZTR 4423  
CHASSIS:  
BODY:  
Twin 12 gauge side frames and 7 gauge transmission  
and engine base plate.  
All body parts made of high density polyethylene. Dent  
and corrosion resistant.  
MOWER DECK:  
13 GA stamped steel construction. Three blades  
combine for a 42” cut width. Cut height approximately  
1-1/2”- 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:  
15.5 HP Briggs & Stratton Intek, 4-Cycle, Single Cylinder,  
Overhead Valve, Air-Cooled, Gasoline, Cast Iron Sleeve  
and Pressure Lube with Spin -On Filter and AVS (Anti-  
vibration System.  
STARTING SYSTEM:  
TIRES:  
Electric by key switch operation with safety interlock blade  
drive.  
Front 11 x 4.00-5 ribbed tread.  
Rear  
18 x 8.50-8 Pro Tech  
RECOMMENDED  
TIRE PRESSURE:  
Front 16-21 PSI  
Rear  
Fuel  
8-14 PSI  
CAPACITIES:  
DIMENSIONS:  
2.4 gallons total  
Engine 1.5 quarts oil  
Width 47” outside rear wheel measurement  
Height 42” to top edge of seat  
Length 72” hitch tab to front bumper  
Weight 520 lbs.  
Additional information provided in service instructions under the individual component.  
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE  
13  
 
SEAT ADJUSTMENT INSTRUCTIONS  
Model ZTR 4423  
1.  
2.  
Raise and push seat assembly forward.  
Loosen five nuts and slide seat forward or backward  
to desired position.  
3.  
4.  
Re-tighten nuts. DO NOT operate mower without  
seat adjustments properly tightened.  
Push seat assembly back to closed position.  
14  
 
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 in “OFF” position.  
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.  
Engage parking brake  
before starting engine.  
CAUTION  
TO SET PARKING BRAKE:  
The hand operated parking brake is located on the  
right end of the mower.  
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.  
15  
 
CONTROLS  
CONTROL LEVERS  
Note: For access to the seat, move control levers to neutral position and  
swing them outward.  
TO GO FORWARD:  
•From neutral position, gently push both control levers forward.  
•To increase speed, move levers further forward.  
TO GO BACKWARD:  
•From neutral position, gently pull both control levers toward you.  
TURNING:  
•Turning is controlled by moving one control lever slightly forward or  
rearward of the other.  
•To turn left, move left lever rearward of the right lever.  
•To turn right, move right lever rearward of the left lever.  
•To turn on mower’s own axis (zero turning radius), stop and move one  
lever to reverse position and the other to forward position.  
BRAKING:  
To brake mower, move both levers in direction opposite of travel.  
LEFT TURN OPPOSITE  
Note: The pressure required to operate the mower is very light.  
16  
 
CONTROLS  
BLADE DRIVE:  
Located on the control panel, on the  
operator’s right.  
To engage the mower blades, pull up on  
the switch.  
To disengage mower blade, 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.  
THROTTLE CONTROL LEVER:  
Located on control panel to operator’s right.  
Throttle control for engine speed.  
Choke for engine starting.  
Throttle control should be set to MAXIMUM  
or wide open setting to ensure adequate  
cooling of the engine and to maintain mower  
deck blade speed while mowing.  
MOWER DECK CUT HEIGHT LIFT LEVER:  
Located to the left of the 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.  
17  
 
OPERATION INSTRUCTIONS  
The safe and successful operation of the 4000  
Series will depend upon the operator having the  
correct knowledge of all controls used on the  
mower and making good judgements about the  
terrain to be mowed.  
NEVER allow anyone to operate the mower  
without complete knowledge of all controls and  
their functions.  
During initial operation, “learning to drive”, set  
throttle at slow speed.  
Sound judgement by the operator will prevent  
accidents.  
TOWING:  
Towing a trailer or other attachment that is too  
heavy could damage the drive or cause the  
mower to become unstable. Limit loads to 250  
pounds or less with this mower.  
18  
 
OPERATION INSTRUCTIONS  
BEFORE OPERATING MOWER:  
1.  
Read and observe all safety instructions on your  
mower and in the manual.  
2.  
Read engine manufacturer’s operating and  
maintenance instructions.  
3.  
4.  
5.  
6.  
7.  
Check engine oil.  
Check fuel cap to be sure it is in place.  
Be sure parking brake is on.  
Mower blade drive is off.  
Know how to stop engine. (Turn key to off position).  
19  
 
OPERATION INSTRUCTIONS  
TESTING OF SAFETY INTERLOCK SYSTEMS:  
Do not operate mower if safety switches are not operating properly.  
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!  
20  
 
OPERATION INSTRUCTIONS  
STARTING INSTRUCTIONS:  
1.  
2.  
Parking brake must be on, and blade drive disengaged.  
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.  
5.  
6.  
Move throttle from “choke” to desired speed position.  
Release parking brake.  
Operate the mower per the “CONTROL” instructions on  
Page 16.  
CAUTION  
Do not operate the engine in an enclosed area  
due to the harmful exhaust gas produced.  
Note: When 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.  
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.  
CAUTION  
Be sure that the deflector is properly  
installed on the discharge chute.  
1,  
2.  
Set engine speed control to the wide open or full  
setting.  
Do Not Attempt To Cut Grass When It Is Wet.  
Wet grass will clog the underside of the deck  
and discharge area.  
3.  
If the grass is tall, place the mower deck cut  
height lever in the top or second notch. “Initially”  
overlap cutting swaths instead of a full swath  
with each pass. Some applications may  
require a second cutting.  
4.  
Keep The Underside Of The Mower Deck Clean.  
Frequent removal of dried grass and dirt will  
allow the clippings to discharge correctly.  
5.  
Maintain Sharp Blade(s) Throughout The Cutting  
Season.  
22  
 
OPERATION INSTRUCTIONS  
GRASS HEIGHT AND CUTTING SUGGESTIONS:  
Do not attempt to cut grass when it is wet.  
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.  
Keep the underside of the mower deck clean.  
Maintain sharp blades throughout the cutting season.  
As a rule of thumb, never cut off more than 1/3 of the total  
grass blade length.  
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 build-up 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  
Bermudagrass  
Bluegrass  
Buffalograss  
Ryegrass  
Tall Fescue  
Zoysiagrass  
Best Cut Heights  
1 - 2”  
2 - 3”  
11/2 -3”  
2 - 3”  
3-31/2  
1 - 3”  
23  
 
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.  
5.  
Do Not Attempt To Cut Grass When It Is Wet.  
Mulching performance will be very poor under  
wet grass conditions.  
Maintain Sharp Blade(s) Throughout The Cutting  
Season. This is very important. Optimal mulching  
performance cannot be obtained with a dull or  
nicked-up blade.  
24  
 
OPERATION INSTRUCTIONS  
MOWING WITH A MULCHING ATTACHMENT  
(continued):  
6.  
7.  
Keep the Underside Of The Mower Deck Clean.  
Remove all grass and dirt build-up from the  
underside of the pan, the baffles and deflectors  
after each use.  
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 satis-  
factory, try one or more of the following tips:  
1.  
2.  
3.  
4.  
5.  
6.  
Raise the height-of-cut setting on your  
mower.  
It may be necessary to cut your grass  
more frequently.  
Operate the mower at a slower ground  
speed.  
Overlap cutting swaths instead of cutting  
a full swath with each pass.  
Mow across the marginal areas a second  
time.  
CUT HIGH - MOW OFTEN!  
25  
 
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.  
2.  
Set engine speed control to the wide open or full  
setting and engage mower before entering area  
to be cut.  
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.  
3.  
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.  
4.  
5.  
Keep The Underside Of The Mower Deck Clean.  
Frequent removal of dried grass and dirt will  
greatly assist in bagging of the clippings.  
Use only the correct blade(s). Some grass  
catching attachments require a “high-lift” blade.  
See your dealer for advice on the type of blade(s)  
needed for your mower.  
6.  
Maintain Sharp Blade(s) Throughout The Cutting  
Season.  
26  
 
OPERATION INSTRUCTIONS  
MOWING WITH A GRASS CATCHER ATTACHMENT  
(continued):  
7.  
8.  
Operate the mower at a slower ground speed than  
when mowing without a grass catching attachment.  
Some mowing applications/use of grass catchers  
may require that an optional weight box be fitted to  
the mower to counter the weight of grass in the bags.  
Please consult with your dealer for more information  
regarding installation and adding weight to the box.  
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 bag.  
27  
 
CARE AND MAINTENANCE  
CAUTION  
Before performing any maintenance, turn off engine,  
allow to cool & remove key.  
Use extreme care when working on machinery.  
Do not wear watch or jewelry. Do not wear loose fitting clothes,  
and observe all common safety practices with tools.  
MAINTENANCE SCHEDULE  
Check deck serpentine belt...........................................after 20 hours break-in  
Check crankcase oil level..........................................................before each use  
Clean grass & debris from muffler & manifold area....................before each use  
Check air intake screen..............................................................after each use  
Clean grass under deck...............................................................after each use  
Check tire pressure......................................................................every 10 hours  
Inspect blades for sharpness.........................................................every 10 hours  
Clean air filter element................................................................every 25 hours  
Grease all zerks...........................................................................every 50 hours  
Check all belts..........................................................................................every 50 hours  
Change engine crankcase oil............................(5 hours break-in) every 50 hours  
Change engine oil filter..............................................................every 50 hours  
Replace air filter element..........................................annually or every 100 hours  
28  
 
CARE AND MAINTENANCE  
ENGINE:  
For complete maintenance and operating information of the engine,  
please refer to the maintenance instructions furnished by the engine  
manufacturer and included in your Zero Turn Radius mower informa-  
tion packet.  
BATTERY:  
Battery contains sulfuric acid electrolyte which is  
poisonous and corrosive.  
CAUTION  
This is a maintenance-free battery and the fluid level cannot  
be checked.  
Charge battery if required.  
OFF SEASON BATTERY STORAGE:  
DO NOT remove battery from mower.  
Clean top of battery and terminals with baking soda and  
water.  
Identify each cable so they can be reconnected to the  
correct terminal.  
Disconnect cables from terminals. ALWAYS disconnect  
ground cable first and reconnect last.  
Charge battery.  
TIRES:  
Correct tire pressure is essential for efficient operation of the  
mower. Check tire pressure periodically. Inflate tires to the  
pressure listed below.  
Front Tires 11 x 4.00-5 16-21 lbs. PSI  
Rear Tires  
18 x 9.50-8 8-14 lbs. PSI  
Lug nuts or lug bolts should be checked regularly for tightness.  
29  
 
CARE AND MAINTENANCE  
CUTTER BLADE MAINTENANCE:  
CAUTION  
Stop engine and remove ignition key for  
safety. Wear heavy, thick gloves when  
holding onto cutter blade, avoid the sharp  
edge of the blade.  
Check sharpness of mower blades after every 10 hours of  
operation. Observe proper blade position prior to removal.  
1.  
2.  
Safely raise front of mower.  
Hold or block blade from  
turning.  
3.  
4.  
Loosen blade nut and remove  
blade.  
When replacing blade, tighten  
blade nut securely. Refer to  
diagram. Be sure blade is  
centered on pilot before tight  
ening nut to 60 ft. lbs.  
Blades should be discarded when worn excessively.  
DANGEROUS!  
DO NOT USE  
BLADE IN THIS  
CONDITION!  
New Blade  
When notch starts,  
discard blade  
30  
 
CARE AND MAINTENANCE  
BELTS:  
Check belts every 50 hours. Replace any belts found to be in  
poor condition.  
BELT TENSION:  
Transaxle Drive Belt:  
P/N 7650  
P/N 7725  
No adjustment required.  
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  
31  
 
CARE AND MAINTENANCE  
MOWER DECK LEVELING PRCEDURE:  
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.  
3.  
Turn each outer blade tip to align with the deck in a side to  
side manner.  
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.  
5.  
Turn each outer blade tip to align with the deck in a front to  
rear manner.  
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 than 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.  
32  
 
CARE AND MAINTENANCE  
DECK REMOVAL:  
1.  
2.  
Place cut height lever in lowest cut position.  
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.  
5.  
Remove hair pin cotter and washer from each deck  
L-rod. Remove L-rods from lift arms. At this point, deck  
will drop down.  
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.  
33  
 
CARE AND MAINTENANCE  
HOT oil may cause burns. Allow  
engine to cool before draining oil.  
CAUTION  
CHANGING THE ENGINE OIL:  
1.  
2.  
3.  
The “Dapco” oil drain valve is located on the left  
side of the engine crankcase.  
Place a suitable container under the drain valve  
hose.  
To drain, turn hex head valve stem counter--  
clockwise with 10mm wrench or socket. Open  
to full open (approximately 7 turns).  
4.  
5.  
6.  
After engine is drained, tighten hex stem.  
Change the oil filter.  
Fill with oil (see steps on next page).  
NOTE: Refer to engine manufacturer’s recommendations  
for frequency of oil changes.  
Hex Head Valve Stem  
34  
 
CARE AND MAINTENANCE  
OIL FILL:  
1.  
3.  
Clean any spilled oil from engine and chassis.  
Refill engine with type, and quantity of oil  
recommended by the engine manufacturer in  
engine literature.  
OIL FILTERS:  
1.  
2.  
Replace filter each time the oil is changed.  
These filters can be obtained from your  
authorized Briggs & Stratton engine dealer  
(P/N 492 932).  
3.  
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.  
35  
 
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.  
36  
 
CARE AND MAINTENANCE  
REAR CHAIN ADJUSTMENT:  
Proper tension for the rear 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.  
37  
 
CARE AND MAINTENANCE  
LUBRICATION:  
CHASSIS:  
(5) grease zerks  
LOCATIONS:  
(1) each front wheel caster  
(1) each mower deck hub  
SERVICE INTERVALS:  
Every 50 hours of operation  
RECOMMENDED GREASE: Name brand wheel bearing or  
multi-purpose grease. Once  
per season or 50 hours of  
operation (3 pumps each)  
Note: Lubrication of the mower deck hubs will help dispel moisture  
within the hub casting. Bearings are of a sealed variety.  
PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS.  
PROTECT YOUR ENVIRONMENT.  
38  
 
CARE AND MAINTENANCE  
ELECTRICAL SYSTEMS:  
Keep all connections clean and tight.  
CLEANING THE MOWER:  
Wash mower periodically. Clean above and below deck.  
High pressure washing and alkaline based soaps can cause  
damage to bearings and other parts of the mower. After  
washing your mower, start the engine and engage the mower  
deck for a few minutes to disperse any water that may have  
accumulated in bearings, pulleys or fans.  
Note: Allow mower to cool before  
washing. If bearings are hot, they  
will draw moisture inside as  
they dry & 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.  
WARRANTY:  
See Warranty Registration Form(sample on page 12).  
PARTS/SERVICE:  
See your Dixon dealer for replacement parts, warranty or service.  
PLEASE HELP PROTECT THE ENVIRONMENT BY AVOIDING ALL  
CHEMCIALS WHICH MAY DAMAGE OR CAUSE HARM TO  
PLANTS AND ANIMALS IN YOUR AREA.  
39  
 
TROUBLESHOOTING  
1.  
ENGINE WON’T TURN OVER  
Mower blades engaged- - - - - - - - - - - - - - - - - - - - - - -disengage blades  
Parking brake not on- - - - - - - - - - - - - - - - - - - - -engage parking brake  
Circuit Breaker Trips- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -reset breaker  
Dead battery- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - charge or replace  
Solenoid- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Ignition switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Starter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
2.  
3.  
ENGINE WILL TURN OVER BUT WON’T START  
No fuel- - - - - - - - - - - - - - - refuel and/or clean or replace fuel filters  
HARD TO START ENGINE  
Fuel line clogged- - - - - - - - - - - - - clean fuel line and check fuel filter  
Faulty fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
4.  
5.  
ENGINE STARTS BUT CUTS OUT  
Water in fuel- - - - - - - - - - - - - - - -drain old fuel-replace with new fuel  
Clogged fuel line- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -check fuel filter  
Fuel tank vent plugged- - - - - - - - - - - - - - - - - - - - - - - - - - - -clean fuel vent  
Faulty fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - check vent  
ENGINE OVERHEATED  
Air intake screen or fins clogged- - - - - -clean intake screen and fins  
Oil level too low or too high- - - - - - - - - - - - - - - - - - - - - - - - - adjust oil level  
Running engine too slow - - - - - - - - - - - - - - - - - - - - - - - -run engine faster  
40  
 
TROUBLESHOOTING  
6.  
7.  
8.  
ENGINE RUNS BUT MOWER WON’T MOVE FORWARD  
Drive belt broken or slipping- - - - - - - - - - - - - - - - - - - - replace drive belt  
Transmission oil low- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - add oil  
Bad transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
MOWER LOSES POWER OR TRANSMISSION OVERHEATS  
Engine air filter-- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -clean or replace  
Transmission damage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Transmission blowing oil out cap - - -overfilled/water contaminated  
ENGINE STALLS WHEN BLADES ARE ENGAGED  
Operator not on seat- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -sit on seat  
Faulty interlock system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Bad blade spindle bearing - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
Deck drive belt not properly routed- - - - - - - - - - - - - - - - - - - - - - - reroute  
Blades blocked by foreign material - - - - - - - - - - - - - -clean under deck  
9.  
DRIVE SYSTEM  
Low on power- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - check belt tension  
Mower pulls to side - - - -check tire inflation/adjust control linkage  
Mower creeps in neutral- - - - - - - - - - - - - - - - - - - -adjust control linkage  
10.  
CUT QUALITY  
Skips in spots- - - - - - - - - - - - check for loose belt/slow ground speed  
Cut uneven left to right - - - - - - - - -check tire inflation/level the deck  
Poor dispersal of grass- - - - - - - - - - -clean deck/check for loose belt  
Ends of grass blades are ragged- - - - - - - - - - - - - - - - - -sharpen blades  
41  
 
STANDARD SERVICE PARTS LIST  
Blades:  
Belts:  
P/N 8688 (Standard/Hi-Lift)  
P/N 6236 (Lo-Lift)  
Engine to Mower Deck - P/N 7725  
Engine to Transmission - P/N 2497  
Serpentine Blade Drive - P/N 6109  
BRIGGS & STRATTON AIR AND OIL FILTER PART NUMBERS:  
Refer to engine manufacturers manual for correct service  
intervals for engine oil changes and air filter maintenance.  
Protect your engine investment, use only original equipment  
filters.  
42  
 
OWNER  
INFORMATION  
DIXON INDUSTRIES, INC.  
a BLOUNT International Inc. Co.  
P.O. Box 1569  
Coffeyville, Ks 67337-0945  
620-251-2000  
FAX 620-251-4117  
Date Purchased _________________________________  
Mower Model Number ____________________________  
Mower Serial Number ____________________________  
Purchased From ________________________________  
Name  
________________________________  
Address  
________________________________  
DATE OIL CHANGED:  
DATE ENGINE TUNED:  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
43  
 
ZTR®Mowers  
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.  
P.O. Box 1569  
Coffeyville, Ks 67337-0945  
620-251-2000  
4000 Series  
4423  
Part No. 13632-0702  
 

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