Dixon Lawn Mower 13088 1100A User Guide

Operator's Manual  
4500 SERIES  
ZTR® MOWERS  
2001  
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INDEX  
SAFETY.............................................................Pages 4 - 9  
WARRANTY POLICY ......................................Page  
SPECIFICATIONS ...........................................Page  
SEAT ADJUSTMENT ......................................Page  
10  
11  
12  
CONTROLS .....................................................Pages 13 - 15  
OPERATION INSTRUCTIONS......................Pages 16 - 21  
CAREAND MAINTENANCE .........................Pages 22 - 31  
STANDARD PARTS LIST ................................Page  
32  
TROUBLESHOOTING ...................................Pages 33 -35  
4500 Series  
Part No. 13088-1100A  
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SAFETY  
RIDING LAWNMOWERS, IF IMPROPERLY OPERATED,  
CAN CAUSE SERIOUS INJURY OR DEATH  
The most common causes of injury to the operator or bystander...  
BLADE CONTACT  
TIP-OVER  
BACK-OVER  
RUN-OVER  
...read and understand this manual to prevent injuries.  
Page 4  
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SAFETY  
SAFETY SYMBOLS  
Safety Alert Symbol  
When you see this symbol,  
BE ALERT to the potential for injury.  
Follow recommended safety precautions and safe operating practices.  
Danger  
indicates an imminently hazardous situation  
which, if not avoided, will result in death or  
serious injury.  
Warning  
indicates a potentially hazardous situation  
which, if not avoided, could result in death or  
serious injury.  
Caution  
indicates a potentially hazardous situation  
which, if not avoided, may result in minor or  
moderate injury. It may also be used to alert  
against unsafe practices.  
Page 5  
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SAFETY  
Thiscuttingmower iscapableofamputatinghands&feet,  
andthrowingobjects.  
Failuretoobservethefollowingsafetyinstructionscouldresult in  
seriousinjuryor 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.  
Nevercarrypassengers.  
Do not mow in reverse unless absolutely necessary. Always look down and behind before and while  
backing.  
Be aware of the mower discharge direction and do not point it at anyone. Do not operate the mower  
without either the entire grass catcher or the deflector in place.  
Slow down before turning.  
Never leave a running mower unattended. Always turn off blades, set parking brake, stop engine, and  
remove key before dismounting.  
Turn off blades when not mowing.  
Stop engine before removing grass catcher or unclogging chute.  
Mow only in daylight or good artificial light.  
Do not operate the mower while under the influence of alcohol or drugs.  
Watch for traffic when operating near or crossing roadways.  
Use extra care when loading or unloading the mower into a trailer or truck.  
Do not ride the mower when loading & unloading.  
Always wear safety goggles or safety glasses with side shields when operating mower.  
Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mower-  
related injuries. These operators should evaluate their ability to operate the riding mower safely enough to  
protect themselves and others from serious injury.  
Follow the manufacturer's recommendation for wheel weights or counterweights.  
Maintain or replace safety and instruction labels, as necessary.  
The Engine Exhaust from this product contains chemicals known to the  
State of California to cause cancer, birth defects or other reproductive harm.  
WARNING:  
Page 6  
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SAFETY  
SLOPE OPERATION:  
Slopes are a major factor related to loss-of-control and tip-over accidents,  
which can result in severe injury or death.  
All slopes require extra caution.  
If you cannot back up the slope or if you feel uneasy on it, do not mow it!  
DO  
Mow across the slope with your Dixon ZTR - never up or down.  
Remove obstacles such as rocks, tree limbs, etc.  
Watch for holes, ruts or bumps. Uneven terrain could overturn the mower. Tall grass can hide obstacles.  
Use slow speed. Tires may lose traction on slopes even though the brakes are functioning properly.  
Use extra care with grass catchers or other attachments. These can change the stability of the mower.  
Keep all movement on the slopes slow and gradual. Do not make sudden changes in speed or direction.  
Avoid starting or stopping on a slope. If tires lose traction, disengage the blades and proceed slowly down the  
slope.  
If front wheels lift off the ground, pull the levers back to stabilize the mower.  
DO NOT  
Do not turn on slopes unless necessary, and then, turn slowly and gradually downhill, if possible.  
Do not mow near drop-offs, ditches, or embankments. The mower could suddenly turn over if a wheel is over  
the edge of a cliff or ditch, or if an edge caves in.  
Do not mow on wet grass. Reduced traction could cause sliding.  
Do not try to stabilize the mower by putting your foot on the ground.  
Do not use grass catcher on steep slopes.  
Page 7  
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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  
moweroperation.  
• Never allow children to operate the mower.  
• Use extra care when approaching blind corners, shrubs, trees, or other objects that  
may obscure vision.  
Page 8  
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SAFETY  
SERVICE:  
Use extra care in handling gasoline and other fuels. They are flammable and vapors are explosive.  
Use only an approved container.  
Never remove gas cap or add fuel with the engine running. Allow engine to cool before refueling. Do not  
smoke.  
Never refuel the mower indoors.  
Never store the mower or fuel container inside a building where there is an open flame.  
If fuel is spilled on clothing, change clothing immediately.  
To prevent fire and explosion caused by static electricity:  
Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always  
place containers on the ground away from your vehicle before filling.  
When practical, remove gas-powered equipment from the truck or trailer and refuel it on the  
ground. If this is not possible, then refuel such equipment on a trailer with a portable  
container, rather than from a gasoline dispenser nozzle.  
If a gasoline 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.  
Never run a mower inside a closed area. The exhaust fumes are toxic.  
Keep nuts and bolts tight, especially blade attachment bolts, and keep equipment in good condition.  
Never tamper with safety devices. Check their proper operation regularly.  
Keep mower free of grass, leaves, or other debris buildup. Clean up oil or fuel spillage. Allow mower to cool  
before storing.  
Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting.  
Never make adjustments or repairs with the engine running.  
Grass catcher components are subject to wear, damage, and deterioration, which could expose moving parts or  
allow objects to be thrown. Frequently check components and replace with original equipment parts, when  
necessary.  
Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves, and use extra caution when servicing  
them.  
Batteries contain sulfuric acid. To prevent burns avoid contact with skin, eyes and clothing. To prevent a fire or  
explosion keep sparks and open flames away from battery.  
Before disconnecting the negative (-) ground cable, make sure all switches are OFF.  
Page 9  
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DIXON INDUSTRIES, INC.  
a BLOUNT company  
AIRPORT INDUSTRIALPARK  
PO BOX 1569  
COFFEYVILLE KS 67337 0945  
316 251 2000  
FAX 316 251 4117  
DIXON LIMITED WARRANTY POLICY - 4500 SERIES  
WARRANTY: Home Owner Application: This Dixon Warranty term is for a period of two (2) years from date of  
purchase. Commercial Application: Dixon mowers used for commercial application are warranted for 90 days from the  
date of purchase. Commercial use is specified as use other than, or in addition to, mowing at owner's primary place of  
residence.  
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.  
2.  
Warranty applies only to original retail purchaser of new and unused mowers and accessories.  
All Dixon warranty must be accomplished by authorized Dixon dealers and in accordance with Dixon  
warranty policy and allowances. All warranty claims must be approved by Dixon Industries, Inc.  
3.  
4.  
5
Battery warranty: Limited to 90 days from date of purchase.  
Accessories Warranty (Grass Catchers, Snow Blades, Covers, etc.): Limited to 90 days from date of purchase.  
Warranty does not apply to damage in transit or incidents of misuse, negligence, accidents, or alteration. The  
use of parts or components other than those supplied by Dixon Industries, Inc. VOIDS ALL WARRANTY.  
6.  
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) Transaxle adjustments.  
(c) Belts/chains/sprockets/cutting blades.  
(d) Engines -- All engines used on Dixon ZTR mowers are warranted by each individual engine  
manufacturer.  
(e) Any costs or expense of providing substitute equipment while repair work is being performed on a  
warranted mower.  
7.  
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.  
Blue/Customer Yellow/Dealer White/Dixon Ind.  
WARRANTY VALIDATION: At the time of sale, selling dealer must review each portion of this warranty document,  
complete the information section below, secure customer's signature and send copy to Dixon Industries, Inc.  
DATE OF PURCHASE______________________Model _______________S/N__________________________  
Dealership  
Address  
Owner'sName  
Address  
Owner'sSignature  
Page 10  
Dealer'sSignature  
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SPECIFICATIONS  
Models ZTR 4515B and 4516K  
CHASSIS:  
BODY:  
Twin 12 gauge side frames and 7 gauge transmission and engine base plate.  
All body parts are made of high density polyethylene. Dent and corrosion resistant.  
Front body contains access panel for battery service.  
MOWERDECKS:  
42" Deck: 13 GA Stamped Steel Construction - 42" Cut Width  
50" Deck 11 GA Fabricated Construction/Reinforcement Ribs - 50" Cut Width  
Cut height approximately 1" to 4" via 7 position lift handle.  
Electricclutch.  
BLADEDRIVE:  
TRANSMISSION:  
ENGINE:  
Each rear wheel is independently driven by a HydroGear IZT hydrostatic drive.  
Model 4515B:  
15.5 HP Vanguard Briggs & Stratton, 4-Cycle, Single Cylinder, Overhead Valve,  
Air-Cooled, Gasoline, Vertical Shaft With Cast Iron Cylinder Sleeve, Oil Pump  
With Integral Oil Filter.  
Model 4516K:  
16 HP Kohler Command 16, 4-Cycle, Single Cylinder, Overhead Valve, Air-  
Cooled, Gasoline, Pressure Lubricated, With Oil Filter, Vertical Shaft, Aluminum  
Head and Block with Cast-Iron Cylinder Liner. Smart Spark Ignition.  
STARTINGSYSTEM:  
TIRES:  
Electric by key switch operation with safety interlock blade drive.  
Front  
Rear  
11 X 4.00 X 5 ribbed tread.  
18 X 8.50 X 8 Multi-Trac  
RECOMMENDED  
TIREPRESSURE:  
Front  
Rear  
16-21 lbs.  
8-14 lbs.  
CAPACITIES:  
Fuel  
2.7 gallons total.  
Engine  
Briggs & Stratton - 1.50 quarts oil.  
Kohler - 2 quarts oil with filter.  
DIMENSIONS:  
Width  
Height  
Length  
Weight  
44" Maximum Track Width  
42" to top edge of seat.  
72" hitch tab to front bumper.  
Power Unit:  
463 lbs.  
w/42" Deck:  
547 lbs.  
w/50" Deck: 603 lbs.  
NOTE:  
Additionalinformationprovidedinserviceinstructionsundertheindividualcomponent.  
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE  
Page 11  
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SEAT ADJUSTMENT  
INSTRUCTIONS  
1.  
2.  
3.  
Place parking brake in ON position. (Pull brake lever up)  
Raise and push seat assembly forward.  
Loosen five nuts, P/N 3205, and slide seat forward or backward to desired position.  
Retighten nuts, P/N 3205.  
DO NOT operate mower without seat adjustments properly tightened.  
4
Raise and push seat assembly and upper body rearward to closed position.  
Page 12  
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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  
startingengine.  
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: Thepressurerequiredtooperatethemowerisvery  
light.  
Page 13  
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CONTROLS  
(left turn opposite)  
TO GO FORWARD:  
From neutral position, gently push both drive levers forward.  
To increase speed, move levers farther forward.  
TO GO BACKWARD:  
From neutral position, gently pull both drive levers toward you.  
TURNING:  
Turning is controlled by moving one drive lever slightly forward or rearward of the other.  
To turn left, move left lever rearward of the right lever.  
To turn "square corners" move lever of desired direction to neutral.  
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, release levers to neutral,  
set parking brake. Park only on level surfaces.  
THROTTLE CONTROL:  
Located on control panel to operator's right.  
Throttle control for engine speed.  
Choke for engine starting.  
ThrottleControlshould beset totheMAXIMUM or wideopen settingtoinsureadequate  
cooling of the engine and to maintain mower deck blade speed while mowing.  
Page 14  
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CONTROLS  
BLADE DRIVE:  
Located on control panel, on operator's right.  
To engage the mower blades, pull up on the  
switch.  
To disengage blades, 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.  
MOWER DECK CUT HEIGHT LIFT LEVER:  
Located to the left of 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.  
Page 15  
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OPERATION INSTRUCTIONS  
Safeand successfuloperation willdepend upon theoperator havingthecorrect knowledgeofallcontrolsused  
on the mower and making good judgements about the terrain to be mowed.  
NEVER allowanyoneto operatethemower without completeknowledgeofallcontrolsand their  
functions.  
Duringinitialoperation, "learningtodrive", set throttleat slowspeed.  
Sound judgement bytheoperator willprevent accidents.  
Drink/Cup Holder located on the left rear fender is for transport or carrying only!  
Mower usage requires that both hands be free to control individual levers.  
DO NOT ATTEMPT operation of mower with any type  
of container or other object in either hand.  
TOWING  
Towingatrailerorotherattachment that istooheavycoulddamagethedriveorcausethemowerto  
becomeunstable. Limit loadsto250poundsorlesson thismower.  
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. Be sure gas cap 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)  
Page 16  
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OPERATION INSTRUCTIONS  
TESTING OF SAFETY INTERLOCK SYSTEMS:  
PARKINGBRAKESWITCH 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.  
CONTROLLEVERSWITCH 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.  
BLADEDRIVESWITCH 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!  
e) Disengage blade drive  
f)with engine running, put parking brake in OFF position  
g) Swing levers in  
h) Engage blade drive  
i) Raise weight 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  
Page 17  
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OPERATION INSTRUCTIONS  
Engage parking brake before starting engine.  
CAUTION  
STARTING INSTRUCTIONS:  
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 14.  
NOTE: While mowing throttle control must be set to the  
MAXIMUM or wide open setting to insure adequate  
cooling of the engine and to maintain mower deck  
bladespeed.  
TO FREE WHEEL MACHINE:  
Should it become necessary to push or  
pull the mower in a non-running mode,  
rotate the lever on top of the right  
hydrostat until it is held in place by the  
wire by-pass keeper. This will engage the  
hydraulic by-pass valves and allow the  
machine to free wheel.  
Remember to disengage the hydraulic by-  
pass valves by pulling the wire by-pass  
keeper toward the rear of the machine.  
This will allow the lever to reposition  
itself for normal drive operation.  
Page 18  
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OPERATION INSTRUCTIONS  
MOWING WITH A MULCHING ATTACHMENT:  
Mulchingorrecyclingthegrassclippingsrequiresatotallydifferent mowingapproachthanwouldbenormal  
when side discharging or bagging the grass. There may be instances or conditions where it is not possible  
to hide all of the recycled or mulched clippings.  
In order to achieve the best results, please read and follow the mulching tips listed below:  
1.  
2.  
Set the engine speed control to the wide open or full setting.  
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.  
4.  
5.  
6.  
7.  
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.  
Do Not Attempt To Cut Grass When It Is Wet. Mulching performance will be very poor under  
wet grass conditions.  
Maintain A Sharp Blade Throughout The Cutting Season. This is very important. Optimal  
mulching performance cannot be obtained with a dull or nicked up blade.  
Keep The Underside Of The Mower Deck Clean. Remove all grass and dirt buildup from the  
underside of the pan, the baffles and deflectors after each use.  
Alternate mower direction. This will evenly disperse the mulched grass clippings over the lawn  
for even fertilization.  
If the mulching quality of the mower does not seem to be satisfactory, try one or more of the  
following tips:  
1.  
2.  
3.  
4.  
5.  
6.  
Raise the height-of-cut setting on your mower.  
It may be necessary to cut your grass more frequently.  
Operate the mower at a slower ground speed.  
Overlap cutting swaths instead of cutting a full swath with each pass.  
Mow across the marginal areas a second time.  
CUT HIGH - MOW OFTEN!  
Page 19  
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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. Some applications may require installation of an "Optional" weight box on the front of the mower  
to offset cut grass weight.  
2. Set engine speed control to the wide open or full setting.  
3.  
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.  
4. 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.  
5.  
Keep The Underside Of The Mower Deck Clean. Frequent removal of dried grass and dirt will greatly  
assist in bagging of the clippings.  
6.  
Maintain Sharp Blades Throughout The Cutting Season. Some grass catching attachments require "Hi-  
Lift" blades.  
7. Operate the mower at a slower ground speed than when mowing without a grass catching attachment.  
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 bags.  
Page 20  
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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 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  
dischargearea.  
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 Blades Throughout The Cutting Season.  
GRASS HEIGHT SUGGESTIONS:  
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  
Zoysia  
2" - 2 1/2"  
1 1/2" - 3"  
1 1/2" - 3"  
1 1/2" - 2"  
3" - 4"  
Blue Grass  
Fescue Blends  
St. Augustine (Mid South)  
St. Augustine (Deep South)  
Tifton Bermuda  
Centipede  
1 1/2"  
1 1/2" - 2"  
1 1/2" - 2"  
2"  
Common Bermuda  
Bahia/Argentina/Pensacola  
Page 21  
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CARE AND MAINTENANCE  
This portion of the owners manual deals with normal service items which can be performed by the owner. Please  
rememberthat ifyouarein doubt astothecorrect serviceprocedurestobefollowed,theseandotherservicesituations  
can be handled by a Dixon ZTR dealer who is familiar with the service of your mower.  
MAINTENANCE SCHEDULE:  
Toinsurealongandtroublefreeservicelifeofallcomponents,aregularandthoroughmaintenance  
schedule should be followed. The following items should be checked after the first (10) hours of  
operation and on a weekly basis, or each (40) hours of use:  
1.  
2.  
3.  
4.  
5.  
6.  
Drive system, belts and controls.  
Mower deck belts.  
Tirepressures.  
Tightness of all nuts and bolts.  
Battery fluid level.  
Engine Oil.  
Before performing any maintenance, shut off engine, allow to cool.  
CAUTION  
ENGINE:  
For engine operating and maintenance information, refer to the engine operating and  
maintenance instructions furnished by the engine manufacturer, supplied with each mower.  
BATTERY: Check the fluid in the battery at frequent intervals.  
Keep fluid level above the plates in each cell, using distilled water.  
OFF-SEASON BATTERYSTORAGE:  
Identify each cable so cables can be reconnected to correct terminals.  
Disconnect cables from terminals  
ALWAYS disconnect ground cable first and reconnect last  
Chargebattery.  
DO NOT remove battery from mower.  
Clean top of battery and terminals with baking soda and water.  
Page 22  
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CARE AND MAINTENANCE  
MOWER BLADE MAINTENANCE:  
NOTE:  
Observe proper blade position prior to removal.  
1. Safely raise front of mower.  
2. Hold or block blade from turning.  
3. Loosen blade nut and remove blade.  
4. When replacing blade, tighten blade nut securely. Refer to diagram.  
Wear heavy, thick gloves when holding onto mower blade, avoid the sharp  
edge of the blade.  
CAUTION  
NOTE: Be sure blade is centered on pilot before tightening nut to 60 ft. lbs. torque.  
Page 23  
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CARE AND MAINTENANCE  
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.  
Page 24  
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CARE AND 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. Ifonesidenowdrivesslightlyfasterthan theother, adjust leverstopwasher  
P/N 5760 on that sidetoreduceforward rangeofcontrollever. Ifleversare  
now uneven at top speed, loosen control lever mounting nut. Rotate lever  
to be even with other side and tighten nut.  
Page 25  
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CARE AND MAINTENANCE  
NEUTRAL ADJUSTMENT  
DRIVE MACHINE UNTIL HYDROSTATS HAVE WARMED UP. WITH ENGINE RUNNING AND THE  
PARKING BRAKE OFF, SWING OUT THE CONTROL LEVERS. IF MACHINE STARTS TO CREEP,  
FOLLOWTHEINSTRUCTIONSBELOW.  
1. Stop theengine, engageparkingbrake, and raiserear offramewith jackor blockssothat rear tiresdonot contact  
the ground.  
2. Swing out the control levers, start the engine and release the parking brake.  
3. Raisetheseat toaccesshydrocontrollinkage. Ifright wheelcreeps, adjust right sidelinkage, and vice-versa. Use  
procedurebelow:  
a. Loosen, but do not remove, the bolt in the control tube P/N 5540.  
b. Loosen Jam nuts on ends of the  
coupler P/N 7736.  
c. If right wheel is creeping forward,  
turn coupler counter clockwise until  
neutralisachieved (clockwisefor left  
side). If right wheel is creeping  
backward,turncouplerclockwiseuntil  
neutralisachieved(counterclockwise  
for left side).  
d. Tighten jam nuts against coupler.  
e. Tighten bolt in control tube.  
4. Lower seat, release parking brake, and swing control levers in. If wheel creeps, repeat steps 3a & 3e.  
5. Stop engine and remove rear of machine from jack or blocks.  
6. 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.  
Page 26  
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CARE AND MAINTENANCE  
MOWER DECK LEVELING PROCEDURE:  
1. Place mower on a smooth, level surface and check tire pressures to insure correct stance. Tires  
should be inflated as follows:  
Front: 16 - 21 lbs  
Rear: 8 - 14 lbs  
2. Turn each outer blade tip to align with the deck in a side to side manner.  
3. Measure from the floor surface up to the bottom of the blade tip on the discharge side of the  
mower. Retain this measurement. Move to the opposite side and check to see if that measurement  
is the same. If adjustment is required, turn nut on one or both of the rear L-rods until both  
measurements are equal.  
4. Turn each outer blade tip to align with the deck in a front to rear manner.  
5. Measure from the floor surface up to the bottom of the blade tips at both the front and rear of the  
blades. Rear of blade tips should be to 1/8" to 3/8" higher that the front of blade tips. If  
adjustment is necessary, turn nut on front L-rod.  
NOTE: This will place the mower deck in a base measurement position. Additional adjustment may  
be required to achieve desired cut for the type of grass or conditions involved.  
Page 27  
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CARE AND 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 groves of all pulleys and that belt idler is  
applying tension to the back side of the belt.  
Page 28  
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CARE AND MAINTENANCE  
HOT oil may cause burns. Allow engine to cool before draining oil.  
CAUTION  
CHANGING THE ENGINE OIL:  
1. The "Dapco" oil drain valve is located on the left side of the engine crankcase  
(Model 4515B) and on the right side of the engine crankcase (Model 4516K).  
2. Place a suitable container under the drain valve. The fitting of a short piece of hose  
will help direct the oil.  
3. To drain turn hex head valve stem counter clockwise with 10mm wrench or socket.  
Open to full open (approximately 7 turns).  
4. After engine is drained tighten hex stem.  
NOTE: Refer toenginemanufacturersrecommendationsforfrequencyofoilchanges.  
Hex Head Valve Stem  
OIL FILL:  
1. Drain oil.  
2. Clean any spilled oil from engine and chassis.  
3. Refill engine with type, and quantity of oil recommended by the engine  
manufacturer in engine literature.  
NOTE: Engineoilchangeson the4500SeriesModelswillrequirereplacement oftheoilfilter.  
ThesefilterscannowbeobtainedfromanyauthorizedDixonDealer.  
PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS.  
-PROTECT YOUR ENVIRONMENT-  
Page 29  
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CARE AND MAINTENANCE  
LUBRICATION:  
CHASSIS:  
(7) grease zerks used on 42" & 50"  
LOCATIONS:  
(1) each front wheel caster tube and front  
wheel hub. (1) each mower deck hub.  
SERVICEINTERVALS:  
Every 50 hours of operation  
RECOMMENDED GREASE:  
Name brand wheel bearing or multi-purpose grease  
Once per season or every 50 hours of operation (3 pumps each).  
Use penetrating lubrication to keep all brake parts functioning smoothly. Lubricate at locations illustrated.  
BRAKE SYSTEM:  
Page 30  
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CARE AND MAINTENANCE  
WHEELS AND TIRES:  
Correct tirepressureisimportantforcorrectoperationof  
mower.  
Front Tires 11 X 4.00 X 5  
Rear Tires 18 X 8.50 X 8  
16-21 PSI  
8-14 PSI  
NOTE: Check lug nuts periodically for tightness.  
Keep all connections clean and tight.  
ELECTRICAL SYSTEMS:  
CLEANING THE MOWER: Wash mower periodically.  
Clean above and below deck.  
NOTE: Allow mower to cool before washing. If  
bearings are hot, they will draw moisture  
inside as they dry and cause corrosion.  
SERIALNUMBERS:  
The serial number is located on frame at rear of engine,  
it will begin with DM.  
WARRANTY:  
Refer to Warranty Registration Form (P/N 5859).  
PARTS/SERVICE:  
See your Dixon dealer for replacement parts, warranty  
or service.  
PLEASE HELP PROTECT THE ENVIRONMENT BY AVOIDING ALL  
CHEMICALS WHICH MAY DAMAGE OR CAUSE HARM TO PLANTS AND  
ANIMALS IN YOUR AREA.  
Page 31  
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STANDARD SERVICE PARTS LIST  
42" DECK:  
BLADES:  
BELTS:  
Standard Hi-Lift:  
Lo-Lift:  
P/N 8688  
P/N 6236  
Engine To Mower Deck:  
SerpentineBelt:  
Engine To Transmission:  
P/N 5861  
P/N 6109  
P/N 5768  
50" DECK"  
BLADES:  
BELTS:  
Standard Hi-Lift:  
Lo-Lift:  
P/N 9444  
P/N 9443  
Engine To Mower Deck:  
SerpentineBelt:  
Engine To Transmission:  
P/N 7174  
P/N 1300  
P/N 5768  
BRIGGS & STRATTON FILTER PART NUMBERS:  
Please refer to Briggs & Stratton Engine Operators Manual for correct service intervals  
for engine oil changes and air filter maintenance.  
Protect your engine investment, use only original equipment filters.  
Air Filter & Precleaner:  
Engine Oil Filter:  
P/N 79002  
P/N 79006  
KOHLER FILTER PART NUMBERS:  
Please refer to Kohler Engine Operators Manual for correct service intervals for engine oil  
changes and air filter maintenance.  
Protect your engine investment, use only original equipment filters.  
Air Filter & Pre-Cleaner:  
Engine Oil Filter:  
P/N 78001  
P/N 78006  
Page 32  
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TROUBLESHOOTING  
MOWER CUT QUALITY:  
Therearemanyvariablesthat can effect thecut qualityofanyridingmower. Typeand conditionsofgrass,  
cut height setting,engineRPM andgroundspeedaresomeofthevariablesthat interact creatingdifferences  
in cut quality. Examination of one or more of the above will generally produce a quality cut.  
TheTroubleshootingChart suggestspracticesandadjustmentsthat maybehelpfulinimprovingcut quality.  
Your Dixon ZTR dealer is also available to provide assistance to you.  
SITUATION  
CAUSES  
REMEDY  
Poor cut quality  
Ground speed  
Reduce mowing speed  
Poor cut quality  
Incorrect engine to  
mower deck belt  
Refer to page 32 for part numbers  
Poor cut quality  
Poor cut quality  
Poor cut quality  
Poor cut quality  
Engine RPM too low  
Dull or bent blade  
Increase engine RPM to maximum  
Sharpen or replace as required  
Un-level mower deck  
Refer to page 27 for deck leveling  
procedure  
Grass buildup under  
mower deck  
Clean out underside of mower deck  
Poor cut quality  
Poor cut quality  
Improper blades  
Refer to page 32 for part numbers  
Uneven tire pressures  
Refer to page 31for correct tire  
pressures  
Page 33  
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TROUBLESHOOTING  
DRIVE SYSTEM:  
SITUATION  
CAUSES  
REMEDY  
Mower creeps in neutral Neutraladjustment  
position  
Refer to page 26 for procedure or consult  
your dealer for repair  
Mower pulls to one side Forward travel speed  
Refer to page 25 for procedure  
or the other  
adjustment  
Loss of power and speed Incorrect or worn drive belt Replacebelt  
on both sides  
Spring on idler arm missing Replace spring  
or broken  
Idler arm will not pivot  
Internal malfunction  
Remove cause of seizure and lubricate  
Consult your dealer for repairs  
Drive system functions  
on one side only  
Incorrect or worn drive belt Replacebelt  
Spring on idler arm missing Replace spring  
or broken  
Idler arm will not pivot  
Internal malfunction  
Remove cause of seizure and lubricate  
Consult you dealer for repairs  
Page 34  
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TROUBLESHOOTING  
ELECTRICAL SYSTEM:  
SITUATION  
CAUSES  
REMEDY  
Starter will not  
Circuit breaker disengaged  
Push button to reset  
turn engine over  
Consult your dealer for repair  
Starter will not  
Dead Battery  
Chargebattery  
turn engine over  
Batterydischarge  
Poor connections on  
battery  
Tighten or replace as required  
Battery water low  
Wrong battery installed in  
mower  
Batterydischarge  
Batterydischarge  
Engine electrical system not Have electrical system checked by your dealer  
functioning correctly  
Engine not being operated  
at full throttle  
Increase engine RPM  
Contact your dealer for information  
NOTE: Electricalsystem failuresaregenerallysimplein nature, alwayschecktheobviousfirst and then  
move onto the more complicated parts used.  
Poorbatteryservice,looseconnections,corrosion,frayedorbroken wiring,aremorelikelythan  
component failure.  
Page 35  
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NOTES  
Page 36  
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NOTES  
Page 37  
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NOTES  
Page 38  
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OWNER  
INFORMATION  
DIXON INDUSTRIES, INC.  
A BLOUNT International Inc. Co.  
PO BOX 1569  
COFFEYVILLE KS 67337 0945  
316 251 2000  
FAX 316 251 4117  
DATE PURCHASED  
MOWER MODEL NUMBER  
MOWER SERIAL NUMBER  
DM-  
PURCHASED FROM  
Name  
Address  
DATE OIL CHANGED:  
DATE ENGINE TUNED:  
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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.  
PO BOX 1569  
COFFEYVILLE KS 67337 0945  
316 251 2000  
4500 Series  
4515B&4516K  
Part No. 13088-1100A  
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