Dixon ZTR 4423 User manual

ZTR®
OPERATOR’S MANUAL
4000 SERIES
2002

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 contained in this manual applies to all
Dixon®ZTR®4000 Series Mowers. Your Dixon dealer
will gladly answer any questions.
See your dealer for warranty service, parts and repairs.

3
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. 13087-0701

4
RIDING LAWN MOWERS,
IFIMPROPERLY OPERATED,
CAN CAUSE SERIOUS INJURY OR DEATH.
The most common causes of injury to the operator or bystander...
...read and understand this manual to prevent injuries.
BLADECONTACT
TIP OVER
RUNOVER
BACK OVER
SAFETY

5
Safety Alert Symbol
When you see this symbol,
BE ALERT to the potential for injury.
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.
Follow recommended safety precautions
and safe operating practices.
SAFETY

6
Failure to observe the following safety
instructions could result in serious injury or death.
GENERALOPERATION:
•Read, understand, and follow all instructions in the
manualandonthemowerbeforestarting.
•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.
•NEVERcarrypassengers.
•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.
•Donotoperatethemowerwithout eitherthe entire
grass catcher or the deflector in place.
•Slow down before turning.
•Neverleavearunning mowerunattended. Always
turn off blades, set parking brake, stop engine and
removekeybeforedismounting.
SAFETY

7
GENERALOPERATION(continued) :
•Turnoff blades when not mowing.
•Stopenginebeforeremovinggrasscatcheror
uncloggingchute.
•Mowonly in daylight orgood artificial light.
•Donot operate the mower whileundertheinfluence
of alcohol or drugs.
•Watchfor trafficwhenoperatingnear or crossing
roadways.
•Useextra care when loading orunloadingthemower
into a trailer or truck. Do not ride the mower when
loadingandunloading.
•Always wear safety goggles or safety glasses with
side shields when operating mower.
•Dataindicates that operators, age 60yearsand
above, areinvolvedina largepercentageofriding
mower-related injuries. These operators should
evaluate their abilitytooperate the ridingmower
safely enough to protect themselves and others
from serious injury.
•Followthemanufacturer’srecommendationfor
wheel weights and counterweights.
•Maintain or replace safety & instruction labels as needed.
WARNING:
TheengineexhaustfromthisproductcontainschemicalsknowntotheStateof
Californiatocausecancer,birthdefectsorotherreproductiveharm.
SAFETY

8
SLOPE OPERATION:
Slopesareamajorfactorrelatedtoloss-of-controlandtip-over
accidents,whichcanresultinsevere injury or death.
Allslopesrequireextracaution.
If you cannot back up the slope or if you feel uneasy on it,
do not mow it!
DO •Mowacrossthe slopewith yourDixon ZTR- neverup or down.
•Removeobstaclessuchasrocks,treelimbs,etc.
•Watchfor holes,ruts orbumps. Uneventerrain couldoverturn the
mower. Tallgrasscan hideobstacles.
•Use slow speed. Tires may lose traction on slopes even though the
brakesare functioningproperly.
•Useextracare withgrasscatchersorother attachments.Thesecan
change the stabilityof themower.
•Keep all movement on the slopes slow and gradual. Do not make
sudden changes in speed or direction.
•Avoidstartingor stoppingonaslope. Iftireslosetraction,disengage
the blades and proceed slowly down the slope.
•Iffrontwheelsliftofftheground,pulltheleversbacktostabilizethe
mower.
DO NOT•
Do not turn on slopes unless necessary, and then, turn slowly and
graduallydownhill,ifpossible.
• Do not mow near drop-offs, ditches, or embankments. The mower
could suddenlyturnover ifa wheelisover theedgeof acliff orditch,
or if an edge caves in.
• Do not mowon wetgrass. Reduced tractioncould causesliding.
• Do not try to stabilize the mower by putting your foot on the ground.
• Do not use grass catcher on steep slopes.
SAFETY

9
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.
• Keepchildren out of themowing area and under the
watchful care of another responsible adult.
•Be alert and turn mower off if a child enters the area.
•Beforeandduringbacking,lookBEHINDandDOWNfor
small children.
•Nevercarrychildren. They may fall off and be seriously
injured orinterferewithsafe moweroperation.
•Neverallowchildrento operatethemower.
•Useextra carewhenapproaching blindcorners,shrubs,
trees, or other objects that may obscure vision.

10
SERVICE:
•Use extra care in handling gasoline and other fuels. They are
flammable and vapors are explosive.
Useonlyanapprovedcontainer.
Neverremovefuelcap oraddfuelwithengine running.
Allowenginetocoolbeforerefueling.
Donotsmokewhilerefueling.
Neverrefuelthemowerindoors.
Neverstorethemowerorfuelcontainerinside abuilding
where there is an open flame.
Iffuelisspilledonclothing,changeclothingimmediately.
Topreventfireandexplosion causedbystaticelectricity:
Neverfill containers inside a vehicle or on a truck
or trailer bed with a plastic liner. Always place
containersonthegroundawayfromyourvehicle
beforefilling.
Whenpractical,removefuel-poweredequipment
from the truck or trailer and refuel it on the
ground. If this is not possible, then refuel such
equipmentonatrailerwithaportablecontainer,
ratherthanfromafueldispensernozzle.
If a fuel dispenser nozzle must be used, keep the
nozzle in contact with the rim of the fuel tank or
containeropeningatalltimesuntilfuelingis
complete. Do not use a nozzle lock-open device.
SAFETY

11
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 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 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 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.
SAFETY

12
DIXON INDUSTRIES, INC.
a BLOUNT company
Airport Industrial Park
P.O. Box 1569
Coffeyville, Ks 67337- 0945
620-251-2000
Fax [phone] DIXON LIMITED WARRANTY POLICY
3000 & 4000 Series
WARRANTY: Home Owner Application: This Dixon Warranty term is for a period of two (2) years
from date of purchase. Commercial Application: Dixon mowers used for commercial application
are warranted for 30 days from the date of purchase. Commercial use is specified as use other
than, or in addition to, mowing at owner’s primary place of residence.
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. Warrantyapplies only to original retail purchaser of new and unused mowers and accessories.
2. AllDixonwarrantymustbeaccomplishedbyauthorizedDixondealersandinaccordancewithDixon
warranty policyandallowances. All warrantyclaimsmust be approvedbyDixon Industries, Inc.
3. Batterywarranty: Limitedto90daysfromdateofpurchase.
4. AccessoriesWarranty (GrassCatchers,Snow Blades, Covers,etc.): Limited to 90daysfrom date of
purchase.
5. Warrantydoes not apply to damage in transit or incidentsofmisuse,negligence,accidents, or
alteration. The use ofparts orcomponents other than those supplied byDixon Industries,Inc. VOIDS
ALLWARRANTY.
6. Thefollowing items arenotcovered by this warrantypolicy:
a. Pick up anddeliverycharges for transportation ofmowerto and from anauthorizedDixon
dealer’splaceof business.
b. Transaxleadjustments.
c. Belts/chains/sprockets/cuttingblades.
d. Engines - All engines used on Dixon ZTR mowers are warranted by the individualengine
manufacturer.
e. Anycosts or expenseofproviding substitute equipmentwhilerepair work isbeing
performed on a warranted mower.
7. Thereis nootherexpress warranty. Impliedwarranties,including thoseofmerchantability andfitness
for a particular purpose, are limited to the same duration of the express warranty, and to the extent
permitted bylawany and allimpliedwarrantiesare excluded. Liabilitiesforconsequential damages
under any and all warranties are excluded.
Blue/Customer Yellow/Dealer White/DixonInd.
WARRANTYVALIDATION: Atthetimeofsale,sellingdealermustrevieweachportionofthiswarranty
document,complete the informationsectionbelow, secure customer’ssignature& send copytoDixon
Industries, Inc.
DATE OF PURCHASE____________________MODEL___________________S/N_______________
_____________________________________ ______________________________________
Owner’s Name Dealership
_____________________________________ ______________________________________
Address Address
______________________________________ _______________________________________
_____________________________ ______________________________
Owner’sSignature Dealer’sSignature

13
SPECIFICATIONS
Model ZTR 4423
CHASSIS: Twin 12 gauge side frames and 7 gauge transmission
and engine base plate.
BODY: Allbody partsmade ofhighdensity polyethylene.Dent
andcorrosionresistant. Frontbodycontainsaccess
panelforbatteryservice.
MOWERDECK: 13GA stampedsteelconstruction.Three blades
combinefor a42”cutwidth. Cut heightapproximately
1”-4”via7-positionlifthandle.
BLADEDRIVE: Electricclutch.
TRANSMISSION: Eachrear wheelis independentlydriven bychainand
sprocketsthroughamechanicalfrictiondrive.
ENGINE: 15.5HPBriggs&StrattonIntek,4-Cycle,Single Cylinder,
Overhead Valve, Air-Cooled, Gasoline, Cast Iron Sleeve
andPressureLubewithSpin -OnFilterand AVS(Anti-
vibrationSystem.
STARTINGSYSTEM: Electricbykeyswitchoperationwithsafetyinterlockblade
drive.
TIRES: Front 11 x 4.00-5 ribbed tread.
Rear 18x9.50-8TurfTracR/S
RECOMMENDED Front 16-21PSI
TIREPRESSURE: Rear 8-14PSI
CAPACITIES: Fuel 2.7gallonstotal
Engine 1.5quartsoil
DIMENSIONS: Width 47” outside rear wheel measurement
Height 42” to top edge of seat
Length 72”hitchtabto frontbumper
Weight 520lbs.
Additionalinformation providedinservice instructionsunder theindividualcomponent.
SPECIFICATIONSSUBJECTTOCHANGEWITHOUTNOTICE

14
SEAT ADJUSTMENT INSTRUCTIONS
Model ZTR 4423
1. Raise and push seat assembly forward.
2. Loosen five nuts and slide seat forward or backward
to desired position.
3. Re-tightennuts. DO NOT operate mowerwithout
seatadjustmentsproperlytightened.
4. Push seat assembly back to closed position.

15
CONTROLS
TheDixonZTR hasauniquetransaxle thatrequiresonlytwo driveleversto
control braking, turning, speed and direction.
Oninitial operation,set throttlespeed onslow. Operate withmower
bladein“OFF”position.
Toavoid“over-controlling” themower, usea lighttouch onthe drive
levers.
Slightmovementsusingfingertipcontrolisallthatisnecessary.
PARKING BRAKE:
The parking brake is designed to hold the mower
frommovingand isnot intendedfor usein stopping
themowerwhile itisinmotion.
Engage parking brake
before starting engine.
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
Allowsthemowertoturnonitsownaxis“ZEROTURNINGRADIUS”. Eachlever
controls one side of the mower.
NOTE: The pressure required to operate the mower is very light.
CAUTION

16
CONTROLS
CONTROLLEVERS
Note: For access to the seat, move control levers to neutral position and
swing them outward.
TOGOFORWARD:
•From neutral position, gently push both control levers forward.
•To increase speed, move levers further forward.
TOGOBACKWARD:
•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.

17
CONTROLS
BLADE DRIVE:
•Located on the control panel, on the
operator’s right.
•To engage the mower blades, pull up on
theswitch.
•To disengage mower blade, push down.
CIRCUITBREAKER:
•Protectionoftheelectricalsystemisby
(1) 15 amp circuit breaker.
•Ifcircuit breakertrips,pushbuttontoreset.
•Ifthisconditionrepeats,consultdealer
for inspectionand repair.
THROTTLECONTROLLEVER:
•Located on control panel to operator’s right.
•Throttle control for engine speed.
•Choke for engine starting.
•Throttlecontrol shouldbesetto 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.
•Controlsthecuttingheight.
•Sevenpositionsofadjustment.
•Move lever in and forward to lower.
•Move lever in and back to raise.
NOTE: Alwaysuse highfor transport.

18
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.

19
OPERATION INSTRUCTIONS
BEFORE OPERATING MOWER:
1. Read and observe all safety instructions on your
mowerandinthemanual.
2. Readenginemanufacturer’soperatingand
maintenanceinstructions.
3. Check engine oil.
4. Check fuel cap to be sure it is in place.
5. Be sure parking brake is on.
6. Mower blade drive is off.
7. Know how to stop engine. (Turn key to off position).

20
OPERATION INSTRUCTIONS
TESTING OF SAFETY INTERLOCK SYSTEMS:
Donotoperate mower if safety switches are not operatingproperly.
PARKING BRAKE SWITCH TEST:
a) Place parking brake in OFF position.
b) Turn ignition switch to START.
ENGINE SHOULD NOT TURN OVER
ORATTEMPTTOSTART!
BLADE DRIVE SWITCH TEST:
a) Place parking brake in ON position.
b)Engageblade drive switch.
c) Turn ignition switch to START.
ENGINE SHOULD NOT TURN OVER
ORATTEMPT TOSTART!
SEAT SWITCH TEST:
a) In a SAFE AREA away from bystanders,
start the engine.
b)Engageblade 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
byanauthorizedDixonZTRdealer!