Dixon ZTR 4518, ZTR 4516, ZTR 4515, 13782-0503 User Manual

4500 Series

Model Year 2004

ZTR®

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® 4500 Series
mowers. Your Dixon dealer will gladly
answer any questions.

See your dealer for warranty service, parts
and repairs.

INDEX

Page

Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . .13

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Seat Adjustment Instructions. . . . . . . . . . . . . . . . .15

Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-18

Operation Instructions. . . . . . . . . . . . . . . . . . 19-30

Care & Maintenance. . . . . . . . . . . . . . . . . . . .31-44

Standard Service Parts List. . . . . . . . . . . . . . . 46-47

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 48-49

4500 Series
Part No. 13782-0503

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

Run Over

Tip 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 observ e 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

Do not mow in reverse unless absolutely necessary.
Always look down and behind before and while braking.

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.

carry passengers.

6

SAFETY

GENERAL OPERATION (continued):

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 mower­related injuries. These operators should evaluate their
ability to operate the riding mower safety enough to
protect themselves and others from serious injury.

Follow the manufacturer’s recommendation for wheel
weights and counterweights.

Maintain or replace safety & instruction labels as
needed.

Warning:

The engine exhaust from this product contains chemicals known to
the State of California to cause cancer; birth defects or other
reproductive harm.

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 requires 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 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.

8

SAFETY

SLOPE OPERATION (continued):

DO (continued):

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.

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 store the mower or fuel container inside a

building where there is an open flame.
If fuel is spilled on clothing, change clothing immedi-

ately.
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, 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.
open device.

Do not use a nozzle lock-

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
build-up. 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 blades 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 fire or
explosion keep sparks and open flames away from
battery.

Before disconnecting the negative (-) ground cable,
make sure all switches are off.

11

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.

12

DIXON LIMITED WARRANTY POLICY

RESIDENTIAL HYDRO

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. 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. Frame, body panels and fenders are warranted for the life of the mower.

2. 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.

3. Warranty applies only to original retail purchaser of new and unusedmowers and
accessories.

4. 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.

5. Battery Warranty: limited to 90 days from date of purchase.

6. Accessories Warranty (grass catchers, snow blades, covers, etc.): Limited to 90 days
from date of purchase.

7. 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 VOIDS ALL WARRANTY.

8. 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 or 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.

9. 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.

13

SPECIFICATIONS

Model ZTR 4515, 4516 & 4518

Chassis: Twin 12 gauge side frames and 7 gauge transmission and engine

Body: All body parts made of high density polyethylene.Dent and

Mower Deck: 42” Deck: 13 GA stamped steel construction-42” cut width

Blade Drive: Electric clutch.
Transmission: Each rear wheel is independently driven by a Hydro Gear IZT

Engine:
Model 4515: 15.5 HP Briggs & Str atton Vanguard, 4 cycle, single cylinder,

Model 4516: 16 HP Kohler Command 460 cc, single cylinder, overhead valve,

Model 4518: 18 HP Kohler Command, twin cylinder, overhead valve, air cooled,

Starting System: Electric-key switch operation w/safety interlock blade drive.
Tires: Front 11 x 4.00-5 ribbed tread (16-21 PSI)

base plate.

corrosion resistant.

50” Deck: 11 GA fabricated construction/reinforcement ribs­50” cut width

hydrostatic drive.

overhead valve, air cooled, gasoline, vertical cast iron cylinder,
pressure lube w/spin-on filter.

air cooled, gasoline, full pressure lube with oil filter, vertical
shaft, aluminum head & block with cast iron cylinder liner.

gasoline, full pressure lube with oil filter, vertical shaft, aluminum
head & block with cast-iron cylinder liners.

Rear 18 x 8.50 x 8 4 ply turf tread (8-14 PSI)

Capacities: Fuel 2.7 gallons

Dimensions: Width 44” maximum track width

Note: Additional information provided in service instructions under the

Engine Oil B&S 1.5 quarts

Kohler 2 quarts

Height 42” to top edge of seat
Length 72” hitch tab to front bumper
Weight power unit: 463 lbs

with 42” deck 547 lbs
with 50” deck-603 lbs

individual component.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.

14

SEAT ADJUSTMENT INSTRUCTIONS

Models ZTR 4515, 4516 & 4518

1. Grasp seat slide adjuster and
move it into adjustment position.

2. Slide seat forward or backward.

3. Release seat slide adjuster.

15

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 control levers forward.

•To increase speed, move levers further forward.

TO GO BACKWARDS

•From neutral position, gently pull control levers toward

you.

TURNING

•T urning is contro lled 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.

16

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.

CAUTION

Engage parking brake
before starting engine.

TO SET PARKING BRAKE:

The hand operated parking brake is located on
the right fender.

T o engage brake, pull lev er up (to the rear).
T o release br ake, move lever forw ard (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.

17

CONTROLS

BLADE DRIVE:

•Located on the control panel, on operator’s right.

•T o engage the mower blade, pull up on the switch.

•T o 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 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.

4515 & 4516

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.

18

:

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

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.

allow anyone to operate the mower without

BEFORE OPERATING MOWER:

1. Read engine manufacturer’ s operating and
maintenance instructions.

2. Read and observe all safety instructions on
your mower and in the manual.

3. Check engine oil.

4. Check fuel cap to be sure it is in place.

5. Be sure parking brake is on.

6. Be sure mower blade drive is off.

7. Know how to stop engine. (Turn key to off
position).

19

OPERATION INSTRUCTIONS

TOWING TRAILERS AND OTHER ATTACHMENTS:

T owing 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

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.

T o 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.

(Unlock Transmission):

20

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.

21

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:

NOTE:

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!

If Any Safety Check FAILS, Do Not

Operate The Mower until the system

has been checked and repaired by an

Authorized Dixon Dealer.

22

OPERATION INSTRUCTIONS

CAUTION Engage parking brake before

starting engine.

STARTING INSTRUCTIONS (4515 & 4516):

1. Parking brake must be on, control levers swung out, 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 throttle from “choke” to desired speed position.

5. Release parking brake.

6. Swing levers in.

7 . Operate the mower per the “CONTROL” instructions on

Page 16.

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.

23

OPERATION INSTRUCTIONS

STARTING INSTRUCTIONS (4518):

1. Parking brake must be on, control levers swung out, and
blade drive disengaged.

2. Engage choke to full 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 throttle to desired speed position.

5. Release parking brake.

6. Swing levers in.

7 . Operate the mower per the “CONTROL ” instructions on

Page 16.

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.

24

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 speed control to the wide open or
full setting.

2.

Do Not Attempt To Cut Grass When It Is Wet.

Wet gr ass 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
CuttingSeason.

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 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 Sharp Blade(s) Throughout The Cutting
Season.

ing performance cannot be obtained with a dull
or nicked up blade.

This is very important. Optimal mulch-

26

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.

If the mulching quality of the mower does not seem
to be satisfactory, try one or more of the following
tips:

a. Raise the height-of-cut setting on your

mower.

b. It may be necessary to cut your grass

more frequently.

c. Operate the mower at a slower ground

speed.

d. Overlap cutting swaths instead of cutting

a full swath with each pass.

e. Mow across the marginal areas a second

time.

f. 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. Set engine speed control to the wide open or
full setting.

2.

Do Not Attempt To Cut Grass When It Is Wet.

Wet grass wi ll 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.

Keep The Underside Of The Mower Deck Clean.

Frequent removal of dried grass and dirt will
greatly assist in bagging of the clippings.

5.

Maintain Sharp Blade(s) Throughout The Cutting
Season.

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.

Some grass catching attachments

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 f or low hanging br anches 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
grass from either the discharge chute or grass
catcher components.

•Keep all attachment bolts tight.

•

Do Not

attachment partially removed.

•Important: Do Not

the mower is stored. Damp grass clippings are a fire
hazard if left in the bag.

operate the mower with the grass catching

leave clippings in the bags while

29

OPERATION INSTRUCTIONS

GRASS HEIGHT & 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 on
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 1 - 2”
Bluegrass 2 - 3”
Buffalograss 1

1/2

-3”
Ryegrass 2 - 3”
Tall Fescue 3-3

1/2

”

Zoysiagrass 1 - 3”

30

CARE & MAINTENANCE

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

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

31

CARE & 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:

CAUTION

•This is a maintenance-free battery and the fluid level cannot be
checked.

•Charge battery if required.

Battery contains sulfuric acid electrolyte which
is poisonous and corrosive.

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 11 x 4.00 X 5 16-21 lbs.
Rear tires 18 x 8.50 x 8 8-14 lbs.

Lug nuts or lug bolts should be checked regularly for tightness.

32

CARE & 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. Safely raise front of mower.

2. Hold or block blade from
turning.

3. Loosen blade bolt and remove
blade.

4. When replacing blade, tighten
blade bolt 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 .

New Blade

When notch starts,
discard blade

33

DANGEROUS!

DO NOT USE
BLADE IN THIS
CONDITION!

CARE & MAINTENANCE

BELTS:

Check belts every 50 hours. Replace any belts found to
be in poor condition.

BELT TENSION:

42” Deck

Mower Deck Serpentine Belt-P/N 6109

Manual adjustment. Refer to illustration below.

Engine to Mower Deck Belt-P/N 5861

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

“L” R od

3/4”

(42”/50” Serpentine)

34

Idler Shock

Mount

Tighten or Loosen

Hex Nut to achieve

this dimension

Hex Nut

CARE & MAINTENANCE

FORWARD TRAVEL SPEED ADJUSTMENT

1. Drive machine until hydrostats have warmed
up.

2. 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.

35

CARE & 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.Swing out the control levers, start the engine and release the

parking brake.

3.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 couplercounter-

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 .

36

CARE & MAINTENANCE

NEUTRAL ADJUSTMENT (continued)

4. Stop engine and remove rear of machine from jack or
blocks.

5. 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.

37

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
deckin 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.

required, turn nut on one or both of the rear
L-rods until both measurements are equal.

If adjustment is

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

rear of the blades.

be to 1/8" to 1/4" higher than the front of
blade tips. If adjustment is necessary, turn
nut on front L-rod.

Rear of blade tips should

both the front and

38

CARE & MAINTENANCE

MOWER DECK LEVELING PROCEDURE

(continued):

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.

39

CARE & 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. Slide shaft from
chassis and mower deck.

4. Remove hair pin cotter and washer from each deck L-rod.
Remove L-rods from lift arms. At this point, deck will drop
down.

5. 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.

40

CARE & MAINTENANCE

LUBRICATION:

CHASSIS: (5) grease zerks
LOCATIONS: (1) each front wheel caster

(1) each mower deck hub

SERVICE INTERVALS: Every 50 hours of operation

or once per season.

RECOMMENDED GREASE: Name brand wheel bearing

or multi-purpose grease
(3 pumps each)

BRAKE SYSTEM:

Use penetrating lubrication to keep all brake parts func­tioning smoothly. Lubricate at locations illustrated.

41

CARE & MAINTENANCE

HOT oil may cause burns. Allow engine to

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. Place a suitable container under the drain valve
hose.

3. To drain, turn hex head valve stem counter­clockwise with a 10mm wrench or socket. Open
to full open (approximately 7 turns).

cool before draining oil.

4. After engine is drained, tighten hex stem.

5. Change oil filter.

6. Fill with oil (see steps on next page).

NOTE: Refe r t o engine manufacturer’s recommenda-

tions for frequency of oil changes.

Hex Head Valve

Stem

42

CARE & MAINTENANCE

CAUTION

HOT oil may cause burns. Allow
engine to cool before draining oil.

OIL FILL:

1. Clean any spilled oil from engine and chassis.

2. 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 may be available from
your local Dixon Dealer.

PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS.

PROTECT YOUR ENVIRONMENT.

43

CARE & 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 information (page 13).

PARTS/SERVICE:

See your Dixon dealer for replacement parts,
warranty or service.

44

CARE & MAINTENANCE

NOTES

45

STANDARD SERVICE PARTS LIST

42” Deck

~Blades~

Hi-Lift - P/N 8688 (Standard)

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~

Hi-Lift - P/N 9444 (Standard)

Lo-Lift - P/N 9443

~Belts~

Engine to Mower Deck - P/N 7174

Serpentine - P/N 1300

Engine to Transmission - P/N 5768

46

STANDARD SERVICE PARTS LIST

BRIGGS & STRATTON AIR AND OIL FILTERS

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. Refer to the Briggs & Stratton
Engine Operator’s Manual or ask your dealer for
correct replacement parts.

KOHLER AIR AND OIL FILTERS

Refer to Kohler 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. Refer to the Kohler Engine
Operator’s Manual or ask your dealer for corr ect
replacement parts.

47

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. ENGINE WILL TURN OVER BUT WON’T START
No fuel- - - - - - - - - - - - - - - refuel and/or clean or replace fuel filters

3. HARD TO START ENGINE
Fuel line clogged- - - - - - - - - - - - - clean fuel line and check fuel filter

Faulty f uel pump- - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer

4. ENGINE STARTS BUT CUTS OUT
Water in fuel- - - - - - - - - - - - - - -dr ain old fuel-replace with new fuel

Clogged fuel line- - - - - - - - - - - - - - - - - - - - - - - - - - check fuel filter
Fuel tank vent plugged- - - - - - - - - - - - - - - - - - - - - -clean fuel vent
Faulty f uel pump- - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer

5. 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

48

TROUBLESHOOTING

6. ENGINE RUNS BUT MOWER WON’T MOVE FORWARD
Drive belt broken or slipping- - - - - - - - - - - - - - - - replace drive belt

T r ansmission oil low- - - - - - - - - - - - - - - - - - - - - - - - - - - - add oil
Damaged transmission- - - - - - - - - - - - - - - - - - - - - -consult dealer
Transmission by-pass may be engaged- - - - disengage(see page 20)

7. MOWER LOSES POWER OR TRANSMISSION OVERHEATS
Engine air filter-- - - - - - - - - - - - - - - - - - - - - - - - - - clean or replace

T ransmission damage- - - - - - - - - - - - - - - - - - - - - - -consult dealer

8. ENGINE STALLS WHEN BLADES ARE ENGAGED
Operator not on seat- - - - - - - - - - - - - - - - - - - - - - - - - -sit on seat
Faulty interlock system- - - - - - - - - - - - - - - - - - - - - - consul t dealer
Fauty blade spindle bearing - - - - - - - - - - - - - - - - - - consul t 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

49

NOTES

50

OWNER’S
INFORMATION

Date of Purchase
Mower Model Number
Mower Serial Number
Purchased From

Name
Address

DIXON INDUSTRIES, INC.
a BLOUNT International Inc. Co.
P .O. Box 1569
Coffeyville, Ks 67337-0945
620-251-2000

FAX [phone]

DATE OIL CHANGED DATE ENGINE TUNED

ZTR®MowersZTR®Mowers

ZTR®Mowers

ZTR®MowersZTR®Mowers

WW

ARNING:ARNING:

W

ARNING:

WW

ARNING:ARNING:

Dixon® and ZTR® are registered trademarks of

DIXON INDUSTRIES, INC.
a BLOUNT International Inc. Co.
P .O. Box 1569
Coffeyville, Ks 67337-0945
620-251-2000

The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects or
other reproductive harm.

Dixon Industries, Inc.

4500 Series

4515, 4516 & 4518

Part No. 13782-0503