Dixon Lawn Mower 8950 598 User Manual

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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