4500 Series
ZTR®
Model Year 2004
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 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 mow-
ing. 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 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.
6
SAFETY
GENERAL OPERATION (continued):
Stop engine before removing grass catcher or unclog-
ging 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 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 attach-
ments. 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 embank-
ments. 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 equip-
ment 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. 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
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. CommercialApplication: Definedasuseotherthan, orinadditionto, mowingatowner’s
primary placeof residence. DixonZTR Residential Hydrounits, usedincommercial
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 unusedmowersand
accessories.
4. All Dixon warranty must be accomplished by authorized Dixon dealers and in accor-
dance with Dixon warranty policy and allowances. All warranty claims must be approved
by Dixon Industries, Inc.
5. BatteryWarranty: limitedto90daysfromdateofpurchase.
6. AccessoriesWarranty(grasscatchers, snowblades, covers, etc.):Limitedto90days
fromdateofpurchase.
7. Warrantydoesnotapplytodamageintransitorincidentsofmisuse, negligence,
accidents, oralteration. Theuseofpartsorcomponentsotherthanthosesuppliedby
Dixon Industries VOIDSALLWARRANTY.
8. The following items are not covered by this warranty policy:
(a) Pickupanddeliverychargesfortransportationofmowertoandfromanauthorized
Dixondealer’splaceofbusiness.
(b) Routinemaintenanceoradjustments.
(c) Beltsorblades.
(d) Engines - All engines used on Dixon ZTR mowers are warranted by each individual
enginemanufacturer.
(e) Anycostsorexpenseofprovidingsubstituteequipmentwhilerepairworkisbeing
performed on a warranted mower.
9. Thereisnootherexpresswarranty. Impliedwarranties, includingthoseofmerchantabil-
ityandfitnessforaparticularpurposearelimitedtothesamedurationoftheexpress
warranty and to the extent permitted by law any and all implied warranties are excluded.
Liabilitiesforconsequentialdamagesunderanyandallwarrantiesareexcluded.
13
SPECIFICATIONS
Model ZTR 4515, 4516 & 4518
Chassis:
Body:
Twin 12 gauge side frames and 7 gauge transmission and 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
Blade Drive:
Electric clutch.
Transmission:
Each rear wheel is independently driven by a Hydro Gear IZT
hydrostatic drive.
Engine:
Model 4515:
15.5 HP Briggs & Stratton Vanguard, 4 cycle, single cylinder,
overhead valve, air cooled, gasoline, vertical cast iron cylinder,
pressure lube w/spin-on filter.
Model 4516:
Model 4518:
16 HP Kohler Command 460 cc, single cylinder, overhead valve,
air cooled, gasoline, full pressure lube with oil filter, vertical
shaft, aluminum head & block with cast iron cylinder liner.
18 HP Kohler Command, twin cylinder, overhead valve, air cooled,
gasoline, full pressure lube with oil filter, vertical shaft, aluminum
head & block with cast-iron cylinder liners.
Starting System:
Tires:
Electric-key switch operation w/safety interlock blade drive.
Front 11 x 4.00-5 ribbed tread (16-21 PSI)
Rear 18 x 8.50 x 8 4 ply turf tread (8-14 PSI)
Capacities:
Dimensions:
Fuel
Engine Oil
2.7 gallons
B&S 1.5 quarts
Kohler 2 quarts
Width
44” maximum track width
42” to top edge of seat
72” hitch tab to front bumper
power unit: 463 lbs
Height
Length
Weight
with 42” deck 547 lbs
with 50” deck-603 lbs
Note: Additional information provided in service instructions under the
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.
3.
Slide seat forward or backward.
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
•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.
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.
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.
17
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.
4518
•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.
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 allow anyone to operate the mower without
complete knowledge of all controls and their func-
tions.
During initial operation, “learning to drive”, set
throttle at slow speed.
Sound judgement by the operator will prevent
accidents.
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:
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.
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:
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.
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 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
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. This is very important. Optimal mulch-
ing performance cannot be obtained with a dull
or nicked up blade.
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 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. 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. 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
grass from 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
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
Bermudagrass
Bluegrass
Buffalograss
Ryegrass
Tall Fescue
Zoysiagrass
Best Cut Heights
1 - 2”
2 - 3”
11/2 -3”
2 - 3”
3-31/2”
1 - 3”
30
CARE & MAINTENANCE
CAUTIO N
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:
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 8.50 x 8
16-21 lbs.
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.
DANGEROUS!
DO NOT USE
BLADE IN THIS
CONDITION!
New Blade
When notch starts,
discard blade
33
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 Shock
Mount
Idler Weldment
“L” Rod
Hex Nut
3/4”
(42”/50” Serpentine)
Tighten or Loosen
Hex Nut to achieve
this dimension
34
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
DRIVEMACHINEUNTILHYDROSTATSHAVEWARMEDUP.
WITHENGINERUNNINGANDTHEPARKINGBRAKEOFF,SWING
OUTTHECONTROLLEVERS. IFMACHINESTARTSTOCREEP,
FOLLOWTHEINSTRUCTIONSBELOW.
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. 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 1/4" higher than the front of
blade tips. If adjustment is necessary, turn
nut on front L-rod.
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 func-
tioning smoothly. Lubricate at locations illustrated.
41
CARE & 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. Place a suitable container under the drain valve
hose.
3. To drain, turn hex head valve stem counter-
clockwise with a 10mm wrench or socket. Open
to full open (approximately 7 turns).
4. After engine is drained, tighten hex stem.
5. Change oil filter.
6. Fill with oil (see steps on next page).
NOTE:
Refer to engine manufacturer’s recommenda-
tions for frequency of oil changes.
Hex Head Valve
Stem
42
CARE & MAINTENANCE
HOT oil may cause burns. Allow
engine to cool before draining oil.
CAUTION
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.
PLEASEDISPOSEOFUSEDOILS ATPROPERCOLLECTIONCENTERS.
PROTECTYOURENVIRONMENT.
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 correct
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 fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer
4. 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- - - - - - - - - - - - - - - - - - - - - - - - - - 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
Transmission 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
Transmission damage- - - - - - - - - - - - - - - - - - - - - - -consult dealer
8. ENGINE STALLS WHEN BLADES ARE ENGAGED
Operator not on seat- - - - - - - - - - - - - - - - - - - - - - - - - -sit on seat
Faulty interlock system- - - - - - - - - - - - - - - - - - - - - - consult dealer
Fauty 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
49
NOTES
50
OWNER’S
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 of Purchase
Mower Model Number
Mower Serial Number
Purchased From
Name
Address
DATE OIL CHANGED
DATE ENGINE TUNED
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. 13782-0503
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