Dixon Lawn Mower 13633 0702 User Guide

ZTR®  
OPERATOR’S MANUAL  
2003  
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INDEX  
Page  
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11  
Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . . . . . . . .14  
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-17  
Operation Instructions. . . . . . . . . . . . . . . . . . . 18-29  
Care & Maintenance. . . . . . . . . . . . . . . . . . . . . .30-42  
Standard Service Parts List. . . . . . . . . . . . . . . . . . . .43  
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .44-45  
4500 Series  
Part No. 13633-0702  
3
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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  
TIP OVER  
RUN OVER  
BACK OVER  
...read and understand this manual to prevent injuries.  
4
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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
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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  
mowing. Stop mower if anyone enters the area.  
•NEVER carry passengers.  
•Do not mow in reverse unless absolutely necessary.  
Always look down and behind before and while backing.  
•Be aware of the mower discharge direction and do not  
point it at anyone.  
•Do not operate the mower without either the entire  
grass catcher or the deflector in place.  
•Slow down before turning.  
•Never leave a running mower unattended. Always turn  
off blades, set parking brake, stop engine and remove  
key before dismounting.  
6
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SAFETY  
GENERAL OPERATION (continued):  
•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 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 safely enough to  
protect themselves and others from serious injury.  
•Follow the manufacturer’s recommendation for wheel  
weights and counterweights.  
Maintain/replace safety & instruction labels as needed.  
The engine exhaust from this product contains chemicals known to the State of  
California to cause cancer, birth defects or other reproductive harm.  
WARNING:  
7
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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 drive and/or 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 radually 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.  
8
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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 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.  
9
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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 fuel cap or add fuel with engine  
running. Allow engine to cool before refueling.  
Do not smoke while refueling.  
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 fuel-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 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  
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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  
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 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 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.  
11  
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DIXON LIMITED WARRANTY POLICY  
RESIDENTIAL HYDRO  
WARRANTY: 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.  
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.  
DIXON ZTR MOWERS ARE WARRANTED AGAINST DEFECTS IN MATERIALS AND  
WORKMANSHIP AND PROVIDES FOR REPLACEMENT OR REPAIR OF PARTS INCLUDING LABOR  
COSTS. THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS AND LIMITATIONS:  
1.  
Warranty applies only to original retail purchaser of new and unused mowers and  
accessories.  
2.  
All Dixon warranty must be accomplished by authorized Dixon dealers and in  
accordance with Dixon warranty policy and allowances. All warranty claims must be  
approved by Dixon Industries, Inc.  
3.  
4.  
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.  
5.  
6.  
Warranty does not apply to damage in transit or incidents of misuse, negligence,  
accidents, or alteration. The use of parts or components other than those supplied  
by Dixon Industries, Inc. VOIDS ALL WARRANTY.  
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/Blades/Hydro filters  
(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 merchant  
ability 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.  
Copies: Pink/Customer  
Yellow/Dealer  
White/Return to 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  
Deck Size  
S/N  
(Owner's Name)  
(Street Address)  
(City/State/Zip)  
(Dealership Name & Dealer Number)  
(Street Address)  
(City/State/Zip)  
(Owner's Signature)  
(Dealer's Signature)  
DIXON INDUSTRIES, INC.  
A BLOUNT International Inc. Co.  
PO BOX 1569  
COFFEYVILLE KS 67337 0945  
PHONE 620 251 2000  
1-877-CUT-MORE  
FAX 620 251 4117  
12  
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SPECIFICATIONS  
Model ZTR 4515, 4516 & 4518  
CHASSIS:  
BODY:  
Twin 12 gauge side frames, 7 gauge transmission & 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  
Cut height approximately 1-1/2” to 4” via 7 position lift handle.  
Electric clutch.  
BLADE DRIVE:  
TRANSMISSION: Each rear wheel is independently driven by a HydroGear IZT  
hydrostatic drive.  
ENGINES:  
Model 4515:  
Model 4516:  
Model 4518:  
15.5 HP Briggs & Stratton Vanguard, 4-Cycle, Single Cylinder,  
Overhead Valve, Air-Cooled, Gasoline, Vertical Shaft with Cast Iron  
Cylinder Sleeve, Full pressure lube with spin-on filter  
16 HP Kohler Command 460 cc, Single Cylinder, Overhead Valve,  
Air Cooled, Gasoline, Pressure Lubricated with oil filter, Vertical  
Shaft, Aluminum Head and Block with Cast-Iron Cylinder Liner.  
18 HP Kohler Command Twin Cylinder, Overhead Valve, Air Cooled,  
Gasoline, Pressure Lubricated with oil filter, Vertical Shaft,  
Aluminum Head and Block with Cast-Iron Cylinder Liner.  
STARTING  
SYSTEM :  
Electric by key switch operation with safety interlock blade drive.  
TIRES:  
Front  
Rear  
11 x 4.00 x 5 ribbed tread  
18 x 8.50 x 8 Turf Trac R/S  
RECOMMENDED Front  
TIRE PRESSURE: Rear  
16-21 PSI  
8-14 PSI  
CAPACITIES:  
Fuel  
2.7 gallons total  
Engine B&S - 1.5 quarts  
Kohler - 2 quarts  
DIMENSIONS:  
Width  
44” maximum track width  
Height 42” to top edge of seat  
Length 72” hitch tab to front bumper  
Weight Power Unit:  
w/42” Deck:  
463 lbs.  
547 lbs.  
603 lbs.  
w/50” Deck:  
Additional information provided in service instructions under the individual component.  
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE  
13  
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SEAT ADJUSTMENT INSTRUCTIONS  
Model ZTR 4515, 4516 & 4518  
1.  
2.  
Raise and push seat assembly forward.  
Loosen five nuts and slide seat forward or  
backward to desired position.  
3.  
4.  
Re-tighten nuts. DO NOT operate mower  
without seat adjustments properly tightened.  
Push seat assembly back to closed position.  
14  
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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 both control levers forward.  
To increase speed, move levers further forward.  
TO GO BACKWARD:  
From neutral position, gently pull both 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.  
15  
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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.  
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.  
16  
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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.  
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.  
4518  
CHOKE CONTROL (4518 only):  
Located on control panel to operator’s right.  
Choke for engine starting.  
MOWER DECK CUT HEIGHT LIFT LEVER:  
Located to the left of the operator.  
Controls the cutting height.  
Seven positions of adjustment.  
Move lever in and forward to lower.  
Move lever in and back to raise.  
NOTE: Always use high for transport.  
17  
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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 functions.  
During initial operation, “learning to drive”, set throttle at  
slow speed.  
Sound judgement by the operator will prevent accidents.  
BEFORE OPERATING MOWER:  
1.  
2.  
Read engine manufacturer’s operating and  
maintenance instructions.  
Read and observe all safety instructions on your  
mower and in the manual.  
Check engine oil.  
Check fuel cap to be sure it is in place.  
Be sure parking brake is on.  
Be sure mower blade drive is off.  
Know how to stop engine. (Turn key to off position).  
3.  
4.  
5.  
6.  
7.  
18  
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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.  
19  
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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.  
20  
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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.  
21  
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OPERATION INSTRUCTIONS  
CAUTION  
Engage parking brake before starting engine.  
STARTING INSTRUCTIONS (4515 & 4516):  
1.  
2.  
3.  
Parking brake must be on, control levers swung out,  
and blade drive disengaged.  
Move throttle control to “choke” position if engine is cold,  
full throttle if warm.  
Insert ignition key and turn to “start” position. When  
engine starts, release ignition key. Key will return to  
“run” position.  
4.  
5.  
6.  
7.  
Move throttle from “choke” to desired speed position.  
Release parking brake.  
Swing levers in.  
Operate the mower per the “CONTROL” instructions on  
Page 15.  
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.  
22  
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OPERATION INSTRUCTIONS  
STARTING INSTRUCTIONS (4518):  
1.  
2.  
3.  
Parking brake must be on, control levers swung out,  
and blade drive disengaged.  
Engage choke to full position if engine is cold, full throttle  
if warm.  
Insert ignition key and turn to “start” position. When  
engine starts, release ignition key. Key will return to “run”  
position.  
4.  
5.  
6.  
7.  
Move throttle to desired speed position.  
Release parking brake.  
Swing levers in.  
Operate the mower per the “CONTROL” instructions on  
Page 15.  
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.  
4518  
23  
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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 the deflector is properly  
installed on the discharge chute.  
1,  
2.  
Set engine speed control to the wide open or full  
setting.  
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 Cutting  
Season.  
24  
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OPERATION INSTRUCTIONS  
GRASS HEIGHT AND 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 an  
adequate moisture conditions and normal thatch  
buildup in a healthy lawn. Some locations and  
applications may require slightly different cut heights.  
If in doubt, consult your local lawn professional for  
assistance.  
Grass Types  
Best Cut Heights  
Bermudagrass  
Bluegrass  
Buffalograss  
Ryegrass  
Tall Fescue  
Zoysiagrass  
1 - 2”  
2 - 3”  
11/2 -3”  
2 - 3”  
3-31/2  
1 - 3”  
25  
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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 of 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.  
5.  
Do Not Attempt To Cut Grass When It Is Wet.  
Mulching performance will be very poor under  
wet grass conditions.  
Maintain Sharp Blade(s) Throughout The  
CuttingSeason. This is very important. Optimal  
mulching performance cannot be obtained with  
a dull or nicked up blade.  
26  
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OPERATION INSTRUCTIONS  
MOWING WITH A MULCHING ATTACHMENT  
(continued):  
6.  
7.  
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.  
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.  
b.  
c.  
d.  
e.  
f.  
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  
cuttinga full swath with each pass.  
Mow across the marginal areas a  
second time.  
CUT HIGH - MOW OFTEN!  
27  
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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.  
2.  
Set engine speed control to the wide open or  
full setting.  
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.  
5.  
Keep The Underside Of The Mower Deck Clean.  
Frequent removal of dried grass and dirt will  
greatly assist in bagging of the clippings.  
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  
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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 grassfrom 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  
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CARE AND MAINTENANCE  
CAUTION  
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  
30  
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CARE AND 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 9.50 x 8  
16-21 lbs.  
8-14 lbs.  
Lug nuts or lug bolts should be checked regularly for tightness.  
31  
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CARE AND 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.  
2.  
3.  
Safely raise front of mower.  
Hold or block blade from turning.  
Loosen blade nut and remove  
blade.  
4.  
When replacing blade, tighten  
blade nut 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  
32  
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CARE AND MAINTENANCE  
BELTS:  
Check belts every 50 hours. Replace any belts found to be in  
poor condition.  
BELT TENSION:  
42” Deck:  
Mower Deck Serpentine Belt  
Manual adjustment. Refer to illustration below.  
Engine to Mower Deck Belt: P/N 5861  
P/N 6109  
Auto tensioner with spring loaded idler. No  
adjustment required.  
50” Deck:  
Mower Deck Serpentine Belt:  
P/N 1300  
Manual adjustment. Refer to illustration below.  
Engine to Mower Deck Belt:  
P/N 7174  
Auto tensioner with spring loaded idler. No  
adjustment required.  
Idler Weldment  
Idler Shock Mount  
“L” Rod  
Hex Nut  
3/4”  
(42”/50” Serpentine)  
Tighten or  
Loosen Hex  
Nut to  
achieve this  
dimension  
33  
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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, FOLLOW THE INSTRUCTIONS  
BELOW.  
1.  
Stop the engine, engage parking brake and raise rear  
of frame with jack or blocks so that rear tires do not  
contact the ground.  
2.  
3.  
Swing out the control levers, start the engine and release  
the parking brake.  
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 coupler  
counter-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.  
34  
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CARE AND MAINTENANCE  
NEUTRAL ADJUSTMENT (continued)  
4.  
5.  
Stop engine and remove rear of machine from jack or  
blocks.  
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.  
35  
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CARE AND MAINTENANCE  
FORWARD TRAVEL SPEED ADJUSTMENT  
1.  
2.  
Drive machine until hydrostats have warmed up.  
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.  
36  
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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.  
37  
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CARE AND MAINTENANCE  
DECK REMOVAL:  
1.  
2.  
Place cut height lever in lowest cut position.  
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.  
5.  
Remove hair pin cotter and washer from each deck  
L-rod. Remove L-rods from lift arms. At this point, deck  
will drop down.  
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.  
38  
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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 4515 &  
4518) and on the right side of the engine  
crankcase (Model 4516).  
2.  
3.  
Place a suitable container under the drain valve  
hose.  
To drain, turn hex head valve stem counter--  
clockwise with a 10mm wrench or socket. Open  
to full open (approximately 7 turns).  
4.  
5.  
6.  
After engine is drained, tighten hex stem.  
Change oil filter.  
Fill with oil (see steps on next page).  
NOTE: Refer to engine manufacturer’s recommendations  
for frequency of oil changes.  
Hex Head Valve Stem  
39  
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CARE AND MAINTENANCE  
HOT oil may cause burns. Allow engine to  
cool before draining oil.  
CAUTION  
OIL FILL:  
1.  
2.  
Clean any spilled oil from engine and chassis.  
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 can now be obtained from any authorized  
Dixon Dealer.  
PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS.  
PROTECT YOUR ENVIRONMENT.  
40  
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CARE AND MAINTENANCE  
LUBRICATION:  
CHASSIS:  
(5) grease zerks  
LOCATIONS:  
(1) each front wheel caster  
(1) each mower deck hub  
SERVICE INTERVALS:  
Every 50 hours of operation  
RECOMMENDED GREASE: Name brand wheel bearing or multi-  
purpose grease. Once per season or  
50 hours of operation(3 pumps each)  
BRAKE SYSTEM:  
Use penetrating lubrication to keep all brake parts  
functioning smoothly. Lubricate at locations illustrated.  
41  
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CARE AND 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 Registration Form (copy on  
page 12).  
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.  
42  
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STANDARD SERVICE PARTS LIST  
42” Deck:  
Blades:  
Standard (Hi-Lift) - P/N 8688  
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:  
Standard (Hi-Lift) - P/N 9444  
Lo-Lift - P/N 9443  
Belts:  
Engine to Mower Deck - P/N 7174  
Serpentine - P/N 1300  
Engine to Transmission - P/N 5768  
BRIGGS & STRATTON AIR AND OIL FILTER PART NUMBERS:  
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.  
Air Filter & Pre-Cleaner Kit - P/N 79002 (4515)  
Engine Oil Filter - P/N 79006 (4515)  
KOHLER AIR AND OIL FILTER PART NUMBERS:  
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 - P/N 78001(4516)  
Air Filter & Pre-Cleaner - P/N 78002 (4518)  
Engine Oil Filter - P/N 78006 (4516 & 4518)  
43  
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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.  
3.  
ENGINE WILL TURN OVER BUT WON’T START  
No fuel- - - - - - - - - - - - - - - refuel and/or clean or replace fuel filters  
HARD TO START ENGINE  
Fuel line clogged- - - - - - - - - - - - - clean fuel line and check fuel filter  
Faulty fuel pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -consult dealer  
4.  
5.  
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- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - check vent  
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  
44  
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TROUBLESHOOTING  
6.  
ENGINE RUNS BUT MOWER WON’T MOVE FORWARD  
Drive belt broken or slipping- - - - - - - - - - - - - - - - - - - - replace drive belt  
Transmission oil low- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - add oil  
Bad transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Transmission by-pass may be on- - - - - - - - - - - -turn off (see page 19)  
7.  
8.  
MOWER LOSES POWER OR TRANSMISSION OVERHEATS  
Engine air filter-- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -clean or replace  
Transmission damage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Transmission blowing oil out cap - - -overfilled/water contaminated  
ENGINE STALLS WHEN BLADES ARE ENGAGED  
Operator not on seat- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -sit on seat  
Faulty interlock system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - consult dealer  
Bad 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  
45  
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NOTES  
46  
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OWNER  
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 Purchased _________________________________  
Mower Model Number ____________________________  
Mower Serial Number ____________________________  
Purchased From ________________________________  
Name  
________________________________  
Address  
________________________________  
DATE OIL CHANGED:  
DATE ENGINE TUNED:  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
___________________  
47  
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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. 13633-0702  
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