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
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