Dixon 13632-0702 manual

4000 SERIES ZTR ® 2003 OPERATORS 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 contained in this [...]

3 INDEX Page Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 2 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . . . . . . . .14 Controls. [...]

4 RIDING LAWN MOWERS, IF IMPROPERLY OPERATED, CAN CAUSE SERIOUS INJURY OR DEATH. The most common causes of injury to the operator or bystander... ...read and understand this manual to prevent injuries. BLADE CONTACT TIP OVER RUN OVER 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 serio[...]

6 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[...]

7 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 loa[...]

8 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 roc[...]

9 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. [...]

10 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 in[...]

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 build- up. Clean up o[...]

12 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[...]

13 SPECIFICATIONS Model ZTR 4423 CHASSIS: Twin 12 gauge side frames and 7 gauge transmission and engine base plate. BODY: 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 lif[...]

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-tighten nuts. DO NOT operate mower without seat adjustments properly tightened. 4. Push seat assembly back to closed position.[...]

15 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 co[...]

16 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: ?[...]

17 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 rep[...]

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 o[...]

19 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. 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 engi[...]

20 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) En[...]

21 OPERATION INSTRUCTIONS STARTING INSTRUCTIONS: 1. Parking brake must be on, and blade drive disengaged. 2. 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. Move throttl[...]

22 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, Set engine s[...]

23 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 m[...]

24 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 b[...]

25 OPERATION INSTRUCTIONS MOWING WITH A MULCHING ATTACHMENT (continued): 6. 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. 7. Alternate mower direction. This will evenly disperse the mulched grass clippings over the lawn for even fertilization.[...]

26 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. Set engine speed control to the wide open or full setting and engage mower before entering area to be cut. 2. Do Not Attempt To Cut Grass When It Is [...]

27 OPERATION INSTRUCTIONS MOWING WITH A GRASS CATCHER ATTACHMENT (continued): 7. Operate the mower at a slower ground speed than when mowing without a grass catching attachment. 8. 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 [...]

28 CARE AND MAINTENANCE CAUTION CAUTION CAUTION CAUTION CAUTION Bef Bef Bef Bef Bef ore perf ore perf ore perf ore perf ore perf or or or or or ming an ming an ming an ming an ming an y maintenance y maintenance y maintenance y maintenance y maintenance , tur , tur , tur , tur , tur n off engine n off engine n off engine n off engine n off engine ,[...]

29 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: • This is a maintenance-free battery and the fluid level cannot be checked. • Charge batter[...]

30 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. Blades should be discarded when worn excessively. DANGEROUS! DO NOT USE BLADE IN THIS CONDITION! When notch starts, discard blade New Blade Check sharpn[...]

31 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 No adjustment required. Engine to Mower Deck Belt: P/N 7725 No adjustment required. Correct belt tension is maintained through a fixed engine location and a spring loaded idler system. A pulsing mo[...]

32 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. 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 th[...]

33 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. S[...]

34 CARE AND MAINTENANCE CHANGING THE ENGINE OIL: 1. The Dapco oil drain valve is located on the left side of the engine crankcase. 2. Place a suitable container under the drain valve hose. 3. To drain, turn hex head valve stem counter-- clockwise with 10mm wrench or socket. Open to full open (approximately 7 turns). 4. After engine is drained[...]

35 CARE AND MAINTENANCE OIL FILL: 1. 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. OIL FILTERS: 1. Replace filter each time the oil is changed. 2. These filters can be obtained from your authorized Briggs & Stratton engine dealer (P/N 4[...]

36 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 infla[...]

37 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 th e upper guide rod. The use of a penetrating lu[...]

38 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 [...]

39 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[...]

40 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- - - - - - - - - - - - - - - - - - - - - - -[...]

41 TROUBLESHOOTING 6. ENGINE RUNS BUT MOWER WONT MOVE FORWARD Drive belt broken or slipping- - - - - - - - - - - - - - - - - - - - replace drive belt Transmission oil low- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - add oil Bad transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult deale[...]

42 STANDARD SERVICE PARTS LIST Blades: P/N 8688 (Standard/Hi-Lift) P/N 6236 (Lo-Lift) Belts: 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 filt[...]

43 OWNER INFORMATION Date Purchased _ ________________________________ Mower Model Number ____________________________ Mower Serial Number ____________________________ Purchased From ___ _____________________________ Name ________________________________ Address ________________________________ DATE OIL CHANGED: DATE ENGINE TUNED: _________________[...]

ZTR®Mowers ZTR®Mowers ZTR®Mowers ZTR®Mowers ZTR®Mowers 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 W W W W W ARNING: ARNING: ARNING: ARNING: ARNING: The engine exhaust from [...]