Dixon ZTR 4000 series 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, and become completely familiar with the controls.
The information in this operator's manual applies to all Dixon@ZTR@4000 Series Model Mowers.
Your Dixon dealer will gladly provide a check-out ride, and answer any questions.
See your dealer for warranty service, parts and repairs.
DIXON INDUSTRIES, INC
A BLOUNT COMPANY
AIRPORT INDUSTRIAL PARK
PO BOX 1569
COFFEYVILLE KS 67337 O945
316 251 2OOO
FAX [phone]

Part No. 8950
September 1995
INDEX
SAFETY ................................................................Pages 1 -6
WARRANTY POLICY ...........................................Page 7
SPECIFICATIONS ................................................Page 8
SEAT ADJUSTMENT............................................Page 9
CONTROLS.......................................................... Pages 10-13
OPERATION INSTRUCTIONS..............................Pages 14-19
CARE AND MAINTENANCE .................................Pages 20-27
STANDARD PARTS LIST .....................................Page 28
TROUBLESHOOTING ..........................................Pages 29 -31

SAFETY
RIDING LAWNMOWERS, IF IMPROPERLY OPERATED,
CAN CAUSE SERIOUS INJURY OR DEATH
The most common causes of injury to the operator or bystander...
TIP-OVER
RUN-OVER
RUN-OVER Pagel
BLADE
CONTAC

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 2

A SAFETY
This cutting mower is capable of amputating hands and 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.
9Stop 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.
Page 3

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.
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 4

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.
Pages

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.
•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, 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. This statement applies to chain drive models 2301, 3000 & 4000
Series.
Page 6

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 90 days from date of purchase.
5. Accessories Warranty (Grass Catchers, Snow Blades, Covers, etc.): Limited to 90 days from date of purchase.
6. Warranty does not apply to damage in transit or incidents of misuse, negligence, accidents, or alteration. The use of parts
or components other than those supplied by Dixon Industries, Inc. VOIDS ALL WARRANTY.
7. The following items are not covered by this warranty policy:
(a) Pick up and delivery charges for transportation of mower to and from an Authorized Dixon Dealer's place of business.
(b) Transaxle adjustments.
(c) Belts / chains / sprockets / cutting blades.
(d) Engines -All engines used on Dixon ZTR mowers are warranted by each individual engine manufacturer.
(e) Any costs or expense of providing substitute equipment while repair work is being performed on a warranted mower.
8. There is no other express warranty. Implied warranties, including those of merchantability and fitness for a particular
purpose, are limited to the same duration of the express warranty, and to the extent permitted by law any and all implied
warranties are excluded. Liabilities for consequential damages under any and all warranties are excluded.
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-__________________
Page 7

SPECIFICATIONS
Models ZTR 4421 & 4422
CHASSIS:
BODY: MOWER
DECK:
BLADE DRIVE:
TRANSMISSION:
ENGINE:
Model 4421:
Model 4422:
STARTING SYSTEM:
TIRES:
Hand welded 11 gauge structural tubing.
All body parts are made of rotational molded, high density polyethylene. Front
body contains access panel for battery service. Seat lifts forward or backward
for a variety of service points in the transmission area.
13 GA stamped steel construction.
(3) blades combine for a 42" cut width.
Cut height approximately 1" to 4" via 8 position lift handle.
Electric clutch.
Each rear wheel is independently driven by chain and sprockets through a
friction, mechanical drive.
13 HP Diamond Series Briggs & Stratton, 4-Cycle, Single Cylinder,
Air-Cooled, Gasoline, Vertical Shaft With Cast Iron Cylinder Sleeve.
14 HP Kohler Command Pro Series, Overhead Valves, Vertical Shaft,
4-Cycle, Air-Cooled With Cast Iron Cylinder Sleeve.
Electric by key switch operation with safety interlock blade drive.
Front 410 X 3.50 X 4 ribbed tread.
Rear 18 X 9.50X8 Turf Trac RS
RECOMMENDED
TIRE PRESSURE:
CAPACITIES:
DIMENSIONS:
Front 16-21 Ibs.
Rear 8-14 Ibs.
Fuel 2.4 gallons total.
Engine Briggs & Stratton -1.25 quarts oil.
Kohler -2 quarts oil with filter.
Width 47" outside rear wheel measurement.
Height 39" to top edge of seat.
Length 67" hitch tab to front bumper.
Weight 480 Ibs.
NOTE: Additional information provided in service instructions under
the individual component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

SEAT ADJUSTMENT INSTRUCTIONS
Models ZTR 4421 & ZTR 4422
1. Place parking brake in ON position. (Pull brake lever up)
2. Raise and push seat assembly and upper body forward.
3. Loosen two front seat adjustment knobs, P/N 3978, and slide seat forward or backward to
desired position.
4. Re-tighten front seat adjustment knobs, P/N 3978.
DO NOT operate mower without seat adjustments properly tightened.
5. Raise and push seat assembly and upper body rearward to closed position.
Page 9

CONTROLS
Page 10

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 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.
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.
QAUTION Engage parking brake before starting engine.
Do not leave engine running for extended periods of time without the parking brake
engaged. Damage to the drive system could result.
TO SET PARKING BRAKE:
The hand operated parking brake is located at left hand side of mower.
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 very light.
A minimum of 1/2 hour should be spent simply driving the mower
without the blade drive engaged.
Page 11

CONTROLS:
TO GO FORWARD:
From neutral position, gently push both drive levers
forward. To increase speed, move levers farther forward.
TO GO BACKWARD:
From neutral position, gently pull both drive levers toward you.
TURNING:
Turning is controlled by moving one drive lever slightly forward or rearward of the
other.
To turn left, move left lever rearward of the right lever.
To turn "square corners" move lever of desired direction to neutral.
To turn on mower's own axis (zero turning radius) stop and move one lever to
reverse position and the other to forward position.
BRAKING:
To brake mower, move both levers in direction opposite of travel, release
levers to neutral, set parking brake. 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 12

CONTROLS:
BLADE DRIVE:
Located on control panel, on operator's right.
To engage the mower blades, lift switch up
lightly and push forward.
To disengage blades, pull switch backward.
Switch is clearly marked "on and off".
MOWER DECK CUT HEIGHT LIFT LEVER:
Located to the right and front of operator.
Controls the cutting height. Eight positions of
adjustment. Move lever in and forward to
lower. Move lever in and back to raise.
NOTE: Always use high for transport.
CIRCUIT BREAKER:
Protection of the electrical system is by
(1)15 amp circuit breaker.
If circuit breaker trips, push button to reset.
If this condition repeats, consult dealer for
inspection and repair.
Page 13

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
their functions.
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 in
the 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.
8. Know how to stop engine. (Turn key to off position)
Page 14

OPERATION INSTRUCTIONS
PARKING BRAKE SWITCH TEST: With parking brake in the OFF position,
engine should not turn over or attempt to
start when the key switch is moved to
the start position.
BLADE DRIVE SWITCH TEST: (Electric Clutch or Manual Drive)
a. With either electric blade drive switch
turned on, or manual lever turned forward,
parking brake in On position, engine
should not turn over or attempt to start
when key switch is moved to the start
position.
b. In a SAFE AREA away from bystanders,
start the engine, place throttle setting at
maximum or full. Engage the blade drive
either through the electric clutch switch or
by turning the manual lever forward.
Raise weight slightly off of seat. Engine
should stop.
c. 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 15
TESTING OF
SAFETY INTERLOCK SYSTEMS:

OPERATION INSTRUCTIONS
STARTING INSTRUCTIONS:
1. Move throttle control to "Choke" position if engine is cold, full throttle if warm.
2. Insert ignition key and turn to "Start" position. When engine starts, release
ignition key. Key will return to "Run" position.
3. Move throttle from "Choke" to desired speed position.
NOTE: While mowing, "blade(s) engaged", 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.
Engine cannot be restarted when blade is engaged or the parking
blade is off.
Safety switches stop engine when operator leaves seat while mower
blade is engaged.
Always turn engine off when leaving mower.
DO NOT rely on safety switches.
Page 16

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 A Sharp Blade Throughout The Cutting Season. This is very important. Optimal
mulching performance cannot be obtained with a dull or nicked up blade.
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 17