ZTR®
OPERATOR’S MANUAL
2003
INDEX
Page
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . . . . . . . .14
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-17
Operation Instructions. . . . . . . . . . . . . . . . . . . 18-29
Care & Maintenance. . . . . . . . . . . . . . . . . . . . . .30-42
Standard Service Parts List. . . . . . . . . . . . . . . . . . . .43
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .44-45
4500 Series
Part No. 13633-0702
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 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.
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/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 drive and/or 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 radually 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
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.
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
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 & 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 LIMITED WARRANTY POLICY
RESIDENTIAL HYDRO
WARRANTY: Home Owner Application: Dixon ZTR Residential Hydro Units, 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 ZTR Residential Hydro Units, used in commercial application are
warranted for a period of 90 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
(c) Belts/Blades/Hydro filters
(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 4515, 4516 & 4518
CHASSIS:
BODY:
Twin 12 gauge side frames, 7 gauge transmission & engine base
plate.
All body parts made of high density polyethylene. Dent and corrosion
resistant.
MOWER DECK:
42” Deck: 13 GA Stamped Steel Construction-42” Cut Width
50” Deck: 11 GA Fabricated Construction/Reinforcement Ribs-50”
Cut Width
Cut height approximately 1-1/2” to 4” via 7 position lift handle.
Electric clutch.
BLADE DRIVE:
TRANSMISSION: Each rear wheel is independently driven by a HydroGear IZT
hydrostatic drive.
ENGINES:
Model 4515:
Model 4516:
Model 4518:
15.5 HP Briggs & Stratton Vanguard, 4-Cycle, Single Cylinder,
Overhead Valve, Air-Cooled, Gasoline, Vertical Shaft with Cast Iron
Cylinder Sleeve, Full pressure lube with spin-on filter
16 HP Kohler Command 460 cc, Single Cylinder, Overhead Valve,
Air Cooled, Gasoline, Pressure Lubricated with oil filter, Vertical
Shaft, Aluminum Head and Block with Cast-Iron Cylinder Liner.
18 HP Kohler Command Twin Cylinder, Overhead Valve, Air Cooled,
Gasoline, Pressure Lubricated with oil filter, Vertical Shaft,
Aluminum Head and Block with Cast-Iron Cylinder Liner.
STARTING
SYSTEM :
Electric by key switch operation with safety interlock blade drive.
TIRES:
Front
Rear
11 x 4.00 x 5 ribbed tread
18 x 8.50 x 8 Turf Trac R/S
RECOMMENDED Front
TIRE PRESSURE: Rear
16-21 PSI
8-14 PSI
CAPACITIES:
Fuel
2.7 gallons total
Engine B&S - 1.5 quarts
Kohler - 2 quarts
DIMENSIONS:
Width
44” maximum track width
Height 42” to top edge of seat
Length 72” hitch tab to front bumper
Weight Power Unit:
w/42” Deck:
463 lbs.
547 lbs.
603 lbs.
w/50” Deck:
Additional information provided in service instructions under the individual component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
13
SEAT ADJUSTMENT INSTRUCTIONS
Model ZTR 4515, 4516 & 4518
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
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.
15
CONTROLS
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. The engine will stop if the
parking brake is engaged while the control levers are
in the drive position.
Engage parking brake
before starting engine.
CAUTION
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.
16
CONTROLS
BLADE DRIVE:
•Located on the control panel, on
operator’s right.
•To engage the mower blade, pull up on
the switch.
•To disengage mower blade, push down.
CIRCUIT BREAKER :
4515 & 4516
•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 (omit for 4518).
•Throttle control should be set to
MAXIMUM or wide open setting to insure
adequate cooling of the engine and to
maintain mower deck blade speed while
mowing.
4518
CHOKE CONTROL (4518 only):
•Located on control panel to operator’s right.
•Choke for engine starting.
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 4500 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.
BEFORE OPERATING MOWER:
1.
2.
Read engine manufacturer’s operating and
maintenance instructions.
Read and observe all safety instructions on your
mower and in the manual.
Check engine oil.
Check fuel cap to be sure it is in place.
Be sure parking brake is on.
Be sure mower blade drive is off.
Know how to stop engine. (Turn key to off position).
3.
4.
5.
6.
7.
18
OPERATION INSTRUCTIONS
TOWING TRAILERS AND OTHER ATTACHMENTS:
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.
TO FREE WHEEL MACHINE (Unlock Transmission):
Always turn off engine before engaging or disengaging
the hydro release (free wheel) lever. Never attempt to
move the lever with the engine running.
Rotate the hydro release lever (on top of right hydro)
until it is held in place by the by-pass keeper. Release
parking brake.
To engage the transmission, pull by-pass keeper, toward
rear of machine so hydro release lever returns to its
normal position.
NOTE: Before pushing or towing tractor, transmission
must be unlocked and parking brake released.
The tractor should never be pulled at more than
2 miles per hour or for any appreciable distance.
19
OPERATION INSTRUCTIONS
TESTING OF SAFETY INTERLOCK SYSTEMS:
PARKING BRAKE SWITCH TEST:
a) Swing out control levers
b) Disengage blade drive switch
c) Put parking brake in OFF position
d) Turn ignition switch to START
Engine should not turn over or attempt to start.
CONTROL LEVER SWITCH TEST:
a) Disengage blade drive switch
b) Put parking brake in ON position
c) Swing control levers in
d) Turn ignition switch to START
Engine should not turn over or attempt to start.
20
OPERATION INSTRUCTIONS
TESTING OF SAFETY INTERLOCK SYSTEMS:
BLADE DRIVE SWITCH TEST:
a) Put parking brake in ON position
b) Swing out control levers
c) Engage blade drive switch
d) 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) Leave levers swung out and parking brake ON
c) Engage blade drive
d) Raise slightly off seat
ENGINE SHOULD STOP!
NOTE: If Any Safety Check FAILS, Do Not Operate
The Mower until the system has been checked
and repaired by an Authorized Dixon Dealer.
21
OPERATION INSTRUCTIONS
CAUTION
Engage parking brake before starting engine.
STARTING INSTRUCTIONS (4515 & 4516):
1.
2.
3.
Parking brake must be on, control levers swung out,
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.
5.
6.
7.
Move throttle from “choke” to desired speed position.
Release parking brake.
Swing levers in.
Operate the mower per the “CONTROL” instructions on
Page 15.
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.
22
OPERATION INSTRUCTIONS
STARTING INSTRUCTIONS (4518):
1.
2.
3.
Parking brake must be on, control levers swung out,
and blade drive disengaged.
Engage choke to full 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.
5.
6.
7.
Move throttle to desired speed position.
Release parking brake.
Swing levers in.
Operate the mower per the “CONTROL” instructions on
Page 15.
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.
4518
23
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.
24
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 an
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
Bermudagrass
Bluegrass
Buffalograss
Ryegrass
Tall Fescue
Zoysiagrass
1 - 2”
2 - 3”
11/2 -3”
2 - 3”
3-31/2
1 - 3”
”
25
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
CuttingSeason. This is very important. Optimal
mulching performance cannot be obtained with
a dull or nicked up blade.
26
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 satisfactory, try one or more of the
following tips:
a.
b.
c.
d.
e.
f.
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
cuttinga full swath with each pass.
Mow across the marginal areas a
second time.
CUT HIGH - MOW OFTEN!
27
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.
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.
Maintain Sharp Blade(s) Throughout The
Cutting Season. 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.
Operate the mower at a slower ground speed
than when mowing without a grass catching
attachment.
28
OPERATION INSTRUCTIONS
MOWING WITH A GRASS CATCHER ATTACHMENT
(continued):
7.
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 grassfrom 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.
29
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 (Kohler engine).......(5 hours break-in) every 100 hours
•Change engine oil filter (Kohler engine).....................................................every 100 hours
•Change engine crankcase oil (B&S engine)..............(5 hours break-in) every 50 hours
•Change engine oil filter (B&S engine)...........................................................every 50 hours
•Replace air filter element..........................................annually or every 100 hours
30
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 information
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
Rear tires
11 x 4.00 X 5
18 x 9.50 x 8
16-21 lbs.
8-14 lbs.
Lug nuts or lug bolts should be checked regularly for tightness.
31
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.
3.
Safely raise front of mower.
Hold or block blade from turning.
Loosen blade nut and remove
blade.
4.
When replacing blade, tighten
blade nut securely. Refer to
diagram. Be sure blade is
centered on pilot before
tightening 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
32
CARE AND MAINTENANCE
BELTS:
Check belts every 50 hours. Replace any belts found to be in
poor condition.
BELT TENSION:
42” Deck:
Mower Deck Serpentine Belt
Manual adjustment. Refer to illustration below.
Engine to Mower Deck Belt: P/N 5861
P/N 6109
Auto tensioner with spring loaded idler. No
adjustment required.
50” Deck:
Mower Deck Serpentine Belt:
P/N 1300
Manual adjustment. Refer to illustration below.
Engine to Mower Deck Belt:
P/N 7174
Auto tensioner with spring loaded idler. No
adjustment required.
Idler Weldment
Idler Shock Mount
“L” Rod
Hex Nut
3/4”
(42”/50” Serpentine)
Tighten or
Loosen Hex
Nut to
achieve this
dimension
33
CARE AND MAINTENANCE
NEUTRAL ADJUSTMENT
DRIVE MACHINE UNTIL HYDROSTATS HAVE WARMED UP. WITH ENGINE
RUNNING AND THE PARKING BRAKE OFF, SWING OUT THE CONTROL
LEVERS. IF MACHINE STARTS TO CREEP, FOLLOW THE INSTRUCTIONS
BELOW.
1.
Stop the engine, engage parking brake and raise rear
of frame with jack or blocks so that rear tires do not
contact the ground.
2.
3.
Swing out the control levers, start the engine and release
the parking brake.
Raise the seat to access hydro control linkage. If right
wheel creeps, adjust right side linkage and vice-versa.
Use procedure below.
a.
Loosen jam nuts on ends of the coupler P/N
7736.
b.
If right wheel is creeping forward, turn coupler
counter-clockwise until neutral is achieved
(clockwise for left side). If right wheel is creeping
backward, turn coupler clockwise until neutral
is achieved (counter-clockwise for left side).
c.
Tighten jam nuts against coupler.
34
CARE AND MAINTENANCE
NEUTRAL ADJUSTMENT (continued)
4.
5.
Stop engine and remove rear of machine from jack or
blocks.
Drive machine with both levers in top speed position. If
one side now drives slightly faster than the other, adjust
lever stop washer P/N 5760 on that side to reduce
forward range of control lever. If levers are now uneven
at top speed, loosen control lever mounting nut. Rotate
lever to be even with other side and tighten nut.
35
CARE AND MAINTENANCE
FORWARD TRAVEL SPEED ADJUSTMENT
1.
2.
Drive machine until hydrostats have warmed up.
Drive on a smooth, level surface with both levers
in top speed position.
3.
If one side now drives slightly faster than the other,
adjust lever stop washer P/N 5760 on that side to
reduce forward range of control lever. If levers are
now uneven at top speed, loosen control lever
mounting nut. Rotate lever to be even with other
side and tighten nut.
36
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 to 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.
37
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 grooves of all pulleys and that
belt idler is applying tension to the back side of the belt.
38
CARE AND MAINTENANCE
HOT oil may cause burns. Allow engine to cool before
draining oil.
CAUTION
CHANGING THE ENGINE OIL:
1.
The “Dapco” oil drain valve is located on the left
side of the engine crankcase (Model 4515 &
4518) and on the right side of the engine
crankcase (Model 4516).
2.
3.
Place a suitable container under the drain valve
hose.
To drain, turn hex head valve stem counter--
clockwise with a 10mm wrench or socket. Open
to full open (approximately 7 turns).
4.
5.
6.
After engine is drained, tighten hex stem.
Change 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
39
CARE AND MAINTENANCE
HOT oil may cause burns. Allow engine to
cool before draining oil.
CAUTION
OIL FILL:
1.
2.
Clean any spilled oil from engine and chassis.
Refill engine with type, and quantity of oil
recommended by the engine manufacturer in
engine literature.
NOTE: Engine oil changes on the 4500 Series Models
will require replacement of the oil filter. These
filters can now be obtained from any authorized
Dixon Dealer.
PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS.
PROTECT YOUR ENVIRONMENT.
40
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)
BRAKE SYSTEM:
Use penetrating lubrication to keep all brake parts
functioning smoothly. Lubricate at locations illustrated.
41
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 and cause corrosion.
SERIAL NUMBERS:
The serial number is located on frame at rear of
engine.
WARRANTY:
Refer to Warranty Registration Form (copy on
page 12).
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.
42
STANDARD SERVICE PARTS LIST
42” Deck:
Blades:
Standard (Hi-Lift) - P/N 8688
Lo-Lift - P/N 6236
Belts:
Engine to Mower Deck - P/N 5861
Serpentine - P/N 6109
Engine to Transmission - P/N 5768
50” Deck:
Blades:
Standard (Hi-Lift) - P/N 9444
Lo-Lift - P/N 9443
Belts:
Engine to Mower Deck - P/N 7174
Serpentine - P/N 1300
Engine to Transmission - P/N 5768
BRIGGS & STRATTON AIR AND OIL FILTER PART NUMBERS:
Refer to Briggs & Stratton Engine Operator’s Manual for
correct service intervals for engine oil changes and air filter
maintenance.
Protect your engine investment, use only original equipment
filters.
Air Filter & Pre-Cleaner Kit - P/N 79002 (4515)
Engine Oil Filter - P/N 79006 (4515)
KOHLER AIR AND OIL FILTER PART NUMBERS:
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 & Pre-Cleaner - P/N 78001(4516)
Air Filter & Pre-Cleaner - P/N 78002 (4518)
Engine Oil Filter - P/N 78006 (4516 & 4518)
43
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
44
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 dealer
Transmission by-pass may be on- - - - - - - - - - - -turn off (see page 19)
7.
8.
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
Mower pulls to side- - - - check tire inflation/adjust control linkage
Mower creeps in neutral- - - - - - - - - - - - - - - - - - - -adjust control linkage
Low on power- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - check belt tension
10.
CUT QUALITY
Cut uneven left to right- - - - - - - - - - - - - check tire inflation/level deck
Ends of grass blades are ragged- - - - - - - - - - - - - - - - - -sharpen blades
Poor dispersal of grass- - - - - - - - - - -clean deck/check for loose belt
Skips in spots- - - - - - - - - - - - check for loose belt/slow ground speed
45
NOTES
46
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:
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47
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
4500 Series
4515, 4516 & 4518
Part No. 13633-0702
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