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Dixon 13633-0702 manual

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Table of contents for the manual

  • Page 1

    4500 SERIES ZTR ® 2003 OPERATORS MANUAL[...]

  • Page 2

    IMPORTANT - READ CAREFULLY The Dixon ® ZTR ® Mower is both easy and fun to operate. However, any power mower must be operated properly to be safe. It is not a toy or a recreational vehicle. Before you start to use the mower, read the operators manual carefully and become completely familiar with the controls. The information contained in this [...]

  • Page 3

    3 INDEX Page Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . . . . . . . .14 Controls. .[...]

  • Page 4

    4 RIDING LAWN MOWERS, IF IMPROPERLY OPERATED, CAN CAUSE SERIOUS INJURY OR DEATH. The most common causes of injury to the operator or bystander... ...read and understand this manual to prevent injuries. BLADE CONTACT TIP OVER RUN OVER BACK OVER SAFETY[...]

  • Page 5

    5 Safety Alert Symbol When you see this symbol, BE ALERT to the potential for injury. 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 serio[...]

  • Page 6

    6 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[...]

  • Page 7

    7 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 loa[...]

  • Page 8

    8 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 roc[...]

  • Page 9

    9 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 adu[...]

  • Page 10

    10 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 [...]

  • Page 11

    11 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[...]

  • Page 12

    12 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 [...]

  • Page 13

    13 SPECIFICATIONS Model ZTR 4515, 4516 & 4518 CHASSIS: Twin 12 gauge side frames, 7 gauge transmission & engine base plate. BODY: 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 Rib[...]

  • Page 14

    14 SEAT ADJUSTMENT INSTRUCTIONS Model ZTR 4515, 4516 & 4518 1. Raise and push seat assembly forward. 2. Loosen five nuts and slide seat forward or backward to desired position. 3. Re-tighten nuts. DO NOT operate mower without seat adjustments properly tightened. 4. Push seat assembly back to closed position.[...]

  • Page 15

    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 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[...]

  • Page 16

    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. TO SET PARKING BRAKE: The hand operated [...]

  • Page 17

    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 : • Protection of the electrical system is by (1) 15 amp circuit breaker. • If circuit breaker trips, push button to reset. • If this condition repeats[...]

  • Page 18

    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 functions. During initial o[...]

  • Page 19

    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 [...]

  • Page 20

    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 i[...]

  • Page 21

    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 lev[...]

  • Page 22

    22 OPERATION INSTRUCTIONS 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 r[...]

  • Page 23

    23 4518 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 pos[...]

  • Page 24

    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 s[...]

  • Page 25

    25 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 m[...]

  • Page 26

    26 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 b[...]

  • Page 27

    27 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[...]

  • Page 28

    28 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 t[...]

  • Page 29

    29 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[...]

  • Page 30

    30 CARE AND MAINTENANCE CAUTION CAUTION CAUTION CAUTION CAUTION Bef Bef Bef Bef Bef ore perf ore perf ore perf ore perf ore perf or or or or or ming an ming an ming an ming an ming an y maintenance y maintenance y maintenance y maintenance y maintenance , tur , tur , tur , tur , tur n off engine n off engine n off engine n off engine n off engine ,[...]

  • Page 31

    31 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: • This is a maintenance-free battery and the fluid level cannot be checked. • Charge battery [...]

  • Page 32

    32 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. Blades should be discarded when worn excessively. DANGEROUS! DO NOT USE BLADE IN THIS CONDITION! When notch starts, discard blade New Blade Check sharpn[...]

  • Page 33

    33 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 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 Serpenti[...]

  • Page 34

    34 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 g[...]

  • Page 35

    35 CARE AND 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[...]

  • Page 36

    36 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. 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 une[...]

  • Page 37

    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 deck in a side to side manner. 3. Measure from the floor surface up to the bottom [...]

  • Page 38

    38 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. S[...]

  • Page 39

    39 CARE AND MAINTENANCE 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 wr[...]

  • Page 40

    40 CARE AND MAINTENANCE HOT oil may cause burns. Allow engine to cool before draining oil. OIL FILL: 1. Clean any spilled oil from engine and chassis. 2. Refill engine with type, and quantity of oil recommended by the engine manufacturer in engine literature. NOTE: Engine oil changes on the 4500 Series Models will require replacement of the oil fil[...]

  • Page 41

    41 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 a[...]

  • Page 42

    42 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[...]

  • Page 43

    43 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 - [...]

  • Page 44

    44 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- - - - - - - - - - - - - - - - - - - - - - -[...]

  • Page 45

    45 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 deale[...]

  • Page 46

    46 NOTES[...]

  • Page 47

    47 OWNER INFORMATION Date Purchased _ ________________________________ Mower Model Number ____________________________ Mower Serial Number ____________________________ Purchased From ___ _____________________________ Name ________________________________ Address ________________________________ DATE OIL CHANGED: DATE ENGINE TUNED: _________________[...]

  • Page 48

    ZTR®Mowers ZTR®Mowers ZTR®Mowers ZTR®Mowers ZTR®Mowers 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 W W W W W ARNING: ARNING: ARNING: ARNING: ARNING: The eng[...]