Dixon ZTR 4515B, ZTR 4516K User Manual
1999 Operator's Manual
4500
SERIES
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® 4500 Series Model Mowers.
Your Dixon dealer will gladly answer any questions.
See your dealer for warranty service, parts and repairs.
DIXON INDUSTRIES, INC.
A BLOUNT International Inc. Co.
PO BOX 1569
COFFEYVILLE KS 67337 0945
316 251 2000
Page 2
INDEX
SAFETY .................................................................Pages 2 - 7
WARRANTY POLICY .............................................. Page 8
SPECIFICATIONS .................................................. Page 9
SEAT ADJUSTMENT............................................. Page 10
CONTROLS ........................................................... Pages 11 - 14
OPERATION INSTRUCTIONS ................................ Pages 15 - 20
CARE AND MAINTENANCE .................................. Pages 21 - 31
STANDARD PARTS LIST ......................................Page 32
TROUBLESHOOTING ............................................Pages 33 - 35
4500 Series
Part No. 5863-0798
SAFETY
RIDING LAWNMOWERS, IF IMPROPERLY OPERATED,
CAN CAUSE SERIOUS INJURY OR DEATH
The most common causes of injury to the operator or bystander...
BLADE CONTACT
...read and understand this manual to prevent injuries.
TIP-OVER
BACK-OVER
Page 4
SAFETY
SAFETY SYMBOLS
Safety Alert Symbol
When you see this symbol,
BE ALERT to the potential for injury.
Follow recommended safety precautions and safe
operating practices.
Danger
indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury.
Warning
indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury.
Caution
indicates a potentially hazardous situation
which, if not avoided, may result in minor or
moderate injury. It may also be used to alert
against unsafe practices.
Page 5
SAFETY
This cutting mower is capable of amputating hands & feet,
and throwing objects.
Failure to observe the following safety instructions could result in
serious injury or death.
GENERAL OPERATION:
• Read, understand, and follow all instructions in the manual and on the mower before
starting.
• Only allow responsible adults, who are familiar with the instructions, to operate the
mower.
• Clear the area of objects such as rocks, toys, wire, etc., which could be picked up and
thrown by the blade.
• Be sure the area is clear of other people before mowing. Stop mower if anyone enters
the area.
• Never carry passengers.
• Do not mow in reverse unless absolutely necessary. Always look down and behind
before and while backing.
• Be aware of the mower discharge direction and do not point it at anyone. Do not
operate the mower without either the entire grass catcher or the deflector in place.
• Slow down before turning.
• Never leave a running mower unattended. Always turn off blades, set parking brake,
stop engine, and remove key before dismounting.
• Turn off blades when not mowing.
• Stop engine before removing grass catcher or unclogging chute.
• Mow only in daylight or good artificial light.
• Do not operate the mower while under the influence of alcohol or drugs.
• Watch for traffic when operating near or crossing roadways.
• Use extra care when loading or unloading the mower into a trailer or truck.
Do not ride the mower when loading & unloading.
WARNING:
Page 6
The Engine Exhaust from this product contains chemicals known to the
State of California to cause cancer, birth defects or other reproductive harm.
SAFETY
SLOPE OPERATION:
Slopes are a major factor related to loss-of-control and tip-over accidents,
which can result in severe injury or death.
All slopes require extra caution.
If you cannot back up the slope or if you feel uneasy on it, do not mow it.
DO
Mow across the slope with your Dixon ZTR - never up or down.
Remove obstacles such as rocks, tree limbs, etc.
Watch for holes, ruts or bumps. Uneven terrain could overturn the mower. Tall grass can hide
obstacles.
Use slow speed.
Use extra care with grass catchers or other attachments. These can change the stability of the
mower.
Keep all movement on the slopes slow and gradual. Do not make sudden changes in speed or
direction.
Avoid starting or stopping on a slope. If tires lose traction, disengage the blades and proceed
slowly down the slope.
If front wheels lift off the ground, pull the levers back to stabilize the mower.
DO NOT
Do not turn on slopes unless necessary, and then, turn slowly and gradually downhill, if possible.
Do not mow near drop-offs, ditches, or embankments. The mower could suddenly turn over if
a wheel is over the edge of a cliff or ditch, or if an edge caves in.
Do not mow on wet grass. Reduced traction could cause sliding.
Do not try to stabilize the mower by putting your foot on the ground.
Do not use grass catcher on steep slopes.
Page 7
CHILDREN:
Tragic accidents can occur if the operator is not alert to the
Children are attracted to lawn mowers and the mowing activity.
NEVER assume children will stay where they were last seen.
SAFETY
presence of children.
Be alert to avoid accidents.
• Keep children out of the mowing area and under the watchful care of another
responsible adult.
• Be alert and turn mower off if a child enters the area.
• Before and during backing, look behind and DOWN for small children.
• Never carry children. They may fall off and be seriously injured or interfere with safe
mower operation.
• Never allow children to operate the mower.
• Use extra care when approaching blind corners, shrubs, trees, or other objects that may
obscure vision.
Page 8
SAFETY
SERVICE:
• Use extra care in handling gasoline and other fuels. They are flammable and vapors
are explosive.
Use only an approved container.
Never remove gas cap or add fuel with the engine running. Allow engine to cool
before refueling. Do not smoke.
Never refuel the mower indoors.
Never store the mower or fuel container inside a building where there is an open
flame.
• Never run a mower inside a closed area. The exhaust fumes are toxic.
• Keep nuts and bolts tight, especially blade attachment bolts, and keep equipment in
good condition.
• Never tamper with safety devices. Check their proper operation regularly.
• Keep mower free of grass, leaves, or other debris buildup. Clean up oil or fuel
spillage. Allow mower to cool before storing.
• Stop and inspect the equipment if you strike an object. Repair, if necessary, before
restarting.
• Never make adjustments or repairs with the engine running.
• Grass catcher components are subject to wear, damage, and deterioration, which
could expose moving parts or allow objects to be thrown. Frequently check
components and replace with original equipment parts, when necessary.
• Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and use extra
caution when servicing them.
• Batteries contain sulfuric acid. To prevent burns avoid contact with skin, eyes and
clothing. To prevent a fire or explosion keep sparks and open flames away from
battery.
Before disconnecting the negative (-) ground cable, make sure all switches are OFF.
• Check to assure that the drive chains are properly adjusted. A loose chain may come
off causing loss of control.
Page 9
DIXON PROTECTION PLUS TWO YEAR LIMITED WARRANTY POLICY
This warranty policy applies to all ZTR 4500 Series mowers purchased on or after September 1, 1997.
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 90 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:
8. There is no other express warranty. Implied warranties, including those of merchantability and fitness
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______________________
(Owner's Name)
(Address)
(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 / 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.
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.
DM-
(Dealership)
(Address)
(Owner's Signature)
Page 10
(Dealer's Signature)
SPECIFICATIONS
Models ZTR 4515B and 4516K
CHASSIS: Twin 12 gauge side frames and 7 gauge transmission and engine base plate.
BODY: All body parts are made of high density polyethylene. Dent and corrosion
resistant. Front body contains access panel for battery service.
MOWER DECKS: 36" Deck: 11 GA Laser Cut Fabricated - 36" Cut Width
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" to 4" via 7 position lift handle.
BLADE DRIVE: Electric clutch.
TRANSMISSION: Each rear wheel is independently driven by a HydroGear IZT hydrostatic drive.
ENGINE:
Model 4515B: 15HP Vanguard Briggs & Stratton, 4-Cycle, Single Cylinder, Overhead
Valve, Air-Cooled, Gasoline, Vertical Shaft With Cast Iron Cylinder
Sleeve, Oil Pump With Integral Oil Filter.
Model 4516K: 16 HP Kohler Command 16, 4-Cycle, Single Cylinder, Overhead Valve,
Air-Cooled, Gasoline, Pressure Lubricated, With Oil Filter, Vertical Shaft,
Aluminum Head and Block with Cast-Iron Cylinder Liner. Smart Spark
Ignition.
STARTING SYSTEM: Electric by key switch operation with safety interlock blade drive.
TIRES: Front 11 X 4.00 X 5 ribbed tread.
Rear 18 X 8.50 X 8 Multi-Trac
RECOMMENDED
TIRE PRESSURE: Front 16-21 lbs.
Rear 8-14 lbs.
CAPACITIES: Fuel 2.7 gallons total.
Engine Briggs & Stratton - 1.50 quarts oil.
Kohler - 2 quarts oil with filter.
DIMENSIONS: Width 44" Maximum Track Width
Height 42" to top edge of seat.
Length 72" hitch tab to front bumper.
Weight Power Unit: 463 lbs.
w/36" Deck: 544 lbs.
w/42" Deck: 541 lbs.
NOTE:
Additional information provided in service instructions under the individual component.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
Page 11
SEAT ADJUSTMENT INSTRUCTIONS
1. Place parking brake in ON position. (Pull brake lever up)
2. Raise and push seat assembly forward.
3. Loosen five nuts, P/N 3205, and slide seat forward or backward to desired position.
Retighten nuts, P/N 3205.
DO NOT operate mower without seat adjustments properly tightened.
4 Raise and push seat assembly and upper body rearward to closed position.
Page 12
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