Dixon ZTR 4516 manual

4500 Series ZTR® Model Year 2004[...]

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 ma[...]

3 INDEX Page Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . .13 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Seat Adjustment Instructions. . . . . . . . . . . . . . . . .15 Controls. . . . . . . . . . . . . . . . . . . . . . . . . .[...]

4 Blade Contact Tip Over Run Over Back Over SAFETY 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.[...]

5 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 hazar[...]

6 F ailure to observe the f o llowing 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, toy[...]

7 GENERAL OPERATION (continued): Stop engine before removing grass catcher or unclog- ging chute. Mow only in daylight or good artificial light. Do not operate the mower while under the influence of alcohol or drugs. W atch for traf fic when operating near or crossing roadways. Use extra care when loading or unloading the mower into a trailer or tr[...]

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 requires extra caution. If you cannot back up the slope or if you feel uneasy on it, do not mow it! DO Mow across the slope with your Dixon ZTR - never up or down. Remove obstacles such as rocks, tre[...]

9 SLOPE OPERATION (continued): DO (continued): Avoid starting or stopping on a slope. If tires lose traction, disengage the blades and proceed slowly down the slope. If front wheels lift off the ground, pull the levers back to stabilize the mower . DO NOT Do not turn on slopes unless necessary , and then, turn slowly and gradually downhill, if poss[...]

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 store the mower or fuel container inside a building where there is an open fl[...]

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 build-up. Clean up oil or fuel s[...]

12 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 ale[...]

13 DIXON LIMITED W ARRANT Y POLICY RESIDENTIAL HYDRO DIXON ZTR MOWERS ARE WARRANTED AGAINST DEFECTS IN MA TERIALS AND WORKMANSHIP AND PROVIDES FOR REPLACEMENT OR REP AIR OF P AR TS INCLUDING LABOR COSTS. THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS AND LIMIT A TIONS. 1. Home Owner Application: Dixon ZTR Residential Hydro units used only at [...]

14 Model ZTR 4515, 4516 & 4518 Chassis: T win 12 gauge side frames and 7 gauge tr ansmission and 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 ribs- 50” cut[...]

15 SEAT ADJUSTMENT INSTRUCTIONS Models ZTR 4515, 4516 & 4518 1. Grasp seat slide adjuster and move it into adjustment position. 2. Slide seat forward or backward. 3. Release seat slide adjuster .[...]

16 CONTROL LEVERS Note: For access to the seat, move control levers to neutral position and swing them outward. TO GO FORWARD • From neutral position, gently push control levers forward. • T o incr ease speed, move lev ers further forward. TO GO BACKWARDS • From neutral position, gently pull control levers toward you. TURNING • T urning is [...]

17 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 parking b[...]

18 BLADE DRIVE: • Located on the control panel, on operator’s right. • T o engage the mower blade, pull up on the switch. • T o disengage mower blade, push down. CIRCUIT BREAKER: • Protection of the electrical system is by (1) 15 amp circuit br eaker . • If circuit breaker trips, push button to reset. • If this condition repeats, cons[...]

19 The safe and successful operation of the 4500 Series will depend upon the operator having the correct knowledge of all controls used on the mower and making good judgements about the terrain to be mowed. NEVER allow anyone to operate the mower without complete knowledge of all controls and their func- tions. During initial operation, “learning[...]

20 TOWING TRAILERS AND OTHER ATTACHMENTS: T owing a trailer or other at tachment 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 .[...]

21 P ARKING BRAKE SWITCH TEST : a ) Swing out control levers b) Disengage blade drive switch c ) Put parking brake in OFF position d) T urn ignition switch to ST AR T 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) T urn [...]

22 BL ADE DRIVE SWITCH TEST : a ) Put parking brake in ON position. b) Swing out control levers. c ) Engage blade drive switch. d) T urn ignition switch to ST ART . Engine should not turn over or attempt to start. SEA T SWIT CH TEST : a ) In a SAFE AREA away from bystanders, start the engine. b) Leave levers swung out and parking brake ON. c ) Enga[...]

23 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 . K ey wil l return to “run” p[...]

24 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 ke y . Key will return to “run” posit[...]

25 SIDE DISCHARGE OF THE CLIPPINGS: In order to achieve optimum performance when Side discharging the grass clippings, please read and follow the tips listed below . Additional information can be found in the troubleshooting guide. CAUTION Be sure that the deflector is properly installed on the discharge chute. 1 . Set engine speed control to the w[...]

26 MOWING WITH A MULCHING ATTACHMENT: Mulching or recycling the grass clippings requires a totally different mowing approach than would be normal when side discharging or bagging the grass. There may be instances or conditions where it is not possible to hide all the recycled or mulched clippings. In order to achieve the best results, please read a[...]

27 MOWING WITH A MULCHING ATTACHMENT ( continued): 6. Keep the Underside Of The Mower Deck Clean. Remove all grass and dirt build-up from the underside of the pan, the baffles and deflectors after each use. 7 . Alternate mower direction. This will evenly disperse the mulched grass clippings over the lawn for even fertilization. If the mulching qual[...]

28 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 At tempt T o Cut Grass When It I s W et. W et grass will clog both the underside of the deck and the [...]

29 CAUTION •W atch for low hanging br anches 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[...]

30 GRASS HEIGHT & CUTTING SUGGESTIONS: Do not attempt to cut grass when it is wet. If the grass is tall, place the mower deck cut height lever in the top or second notch. “Initially” overlap cutting swaths instead of a full swath with each pass. Some applications may require a second cutting. Keep the underside of the mower deck clean. Main[...]

31 CAUTION CAUTION CAUTION CAUTION 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........[...]

32 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 Z ero T urn R adius mower information packet. BATTERY: •This is a maintenance-free battery and the fluid level cannot be checked. •Charge battery if required. OFF SEA[...]

33 CUTTER BLADE MAINTENANCE: CAUTION Stop engine and remove ignition key for safet y . Wear hea vy , thick gloves when holding onto cutter blade, avoid the sharp edge of the blade. Blades should be discarded when worn excessiv ely . DANGEROUS! DO NOT USE BLADE IN THIS CONDITION! When notch starts, discard blade New Blade CARE & MAINTENANCE Chec[...]

34 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. Re fer 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 Manu[...]

35 FORWARD TRAVEL SPEED ADJUSTMENT 1 . Drive machine until hydrostats have warmed up. 2 . Drive on a smooth, level surface with both levers in top speed position. 3 . If one side now drives slightly faster than the other , adjust lever stop washer P/N 5760 on that side to reduce forward range of control lever . If levers are now uneven at top speed[...]

36 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. Swing out t[...]

37 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 f aster than the other , adjust lever stop washer P/N 5760 on that side to reduce forward r ange of control lever . If levers are now uneven at top speed, loosen co[...]

38 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 . T urn each outer blade tip to align with the deck in a side to side manner . 3 . Measure from the floor surface up to the bo[...]

39 MOWER DECK LEVELING PROCEDURE (continued): NOTE: This will place the mower deck in a base measurement position. Additional adjustment may be required to achieve desired cut for the type of grass or conditions involved. CARE & MAINTENANCE[...]

40 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 chas[...]

41 LUBRICATION: CHASSIS: (5) grease zerks LOCA TIONS: (1) each front wheel caster (1) each mower deck hub SERVICE INTERVALS: Every 50 hours of operation or once per season. RECOMMENDED GREASE: Name brand wheel bearing or multi-purpose grease (3 pumps each) BRAKE SYSTEM: Use penetrating lubrication to keep all brake parts func- tioning smoothly . Lu[...]

42 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 . T o drain, turn hex head v alve stem counter- clockwise with a 10mm wrench or socket. O[...]

43 CARE & 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[...]

44 CARE & MAINTENANCE ELECTRICAL SYSTEMS: Keep all connections clean and tight. CLEANING THE MOWER: W ash 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 minu[...]

45 NOTES CARE & MAINTENANCE[...]

46 STANDARD SERVICE PARTS LIST 42” Deck ~Blades~ Hi-Lift - P/N 8688 (Standard) Lo-Lift - P/N 6236 ~Belts~ Engine to Mower Deck - P/N 5861 Serpentine - P/N 6109 Engine to T r ansmission - P/N 5768 50” Deck ~Blades~ Hi-Lift - P/N 9444 (Standard) Lo-Lift - P/N 9443 ~Belts~ Engine to Mower Deck - P/N 7174 Serpentine - P/N 1300 Engine to T r ansmiss[...]

47 STANDARD SERVICE PARTS LIST BRIGGS & STRATTON AIR AND OIL FILTERS Re fer to Briggs & Str at ton Engine Operator’ s Manual fo r correct service intervals for engine oil changes and air filter maintenance. Protect your engine investment, use only original equipment filters. Refer to the Briggs & Stratton Engine Operator’ s Manual o[...]

48 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 [...]

49 TROUBLESHOOTING 6. ENGINE RUNS BUT MOWER WON’ T MOVE FORWARD Drive belt broken or slipping- - - - - - - - - - - - - - - - replace drive belt T r ansmission oil low- - - - - - - - - - - - - - - - - - - - - - - - - - - - add oil Damaged transmission- - - - - - - - - - - - - - - - - - - - - -consult dealer T r ansmission by-pass ma y be engaged- [...]

50 NOTES[...]

Name Address DA TE OIL CHANGED DA TE ENGINE TUNED DIXON INDUSTRIES, INC. a BLOUNT International Inc. Co. P .O. Box 1569 Coffeyville, Ks 67337-0945 620-251-2000 F AX 620-251-4117 OWNER’S INFORMATION Date of Purchase Mower Model Number Mower Serial Number Purchased From[...]

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. 13782-0503 W W W W W ARNING: ARNING: ARNING: ARNING: ARNING: The en[...]