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Dixon ZTR 4516K manual

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Table of contents for the manual

  • Page 1

    4500 SERIES 1999 Operator's Manual[...]

  • Page 2

    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 in thi[...]

  • Page 3

    INDEX SAFETY ................................................................. Pages 2 - 7 WARRANTY POLICY .............................................. Page 8 SPECIFICATIONS .................................................. Page 9 SEAT ADJUSTMENT ............................................. Page 10 CONTROLS .....................................[...]

  • Page 4

    Page 4 ...read and understand this manual to prevent injuries. TIP-OVER BACK-OVER BLADE CONTACT SAFETY RIDING LA WNMOWERS, IF IMPROPERL Y OPERA TED, CAN CAUSE SERIOUS INJUR Y OR DEA TH The most common causes of injury to the operator or bystander ...[...]

  • Page 5

    Page 5 SAFETY SAFETY SYM BOLS 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 w[...]

  • Page 6

    Page 6 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 [...]

  • Page 7

    Page 7 SAFETY SLOPE OPERATION: Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes 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[...]

  • Page 8

    Page 8 SAFETY CHILDREN: T ragic accident s 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 respons[...]

  • Page 9

    Page 9 SAFETY SERVICE: • Use extra care in handling gasoline and other fuels. They are flammable and vapors are explosive. Use only an approved container. Never remove 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 b[...]

  • Page 10

    Page 10 WARRANTY: The Dixon Protection Plus Warranty term is for a period of two (2 ) years from 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 applie[...]

  • Page 11

    Page 11 SPECIFICA TIONS Models ZTR 4515B and 4516K CHASSIS: Twin 12 gauge side frames and 7 gauge transmission and engine base plate. BODY: All body parts are made of high density polyethylene. Dent and corrosion resistant. Front body contains access panel for battery service. MOWER DECKS: 36" Deck: 11 GA Laser Cut Fabricated - 36" Cut Wi[...]

  • Page 12

    Page 12 SEA T ADJUSTMENT INSTRUCTIONS 1 . Place parking brake in ON position. (Pull brake lever up) 2 . Raise and push seat assembly forward. 3 . 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 assemb[...]

  • Page 13

    Page 13 CONTROLS DECK HEIGHT ADJUSTMENT LEVER CONTROL LEVERS PARKING BRAKE LEVER LIGHT SWITCH BLADE DRIVE SWITCH IGNITION SWITCH FRONT OF MACHINE THROTTLE CONTROL CIRCUIT BREAKER[...]

  • Page 14

    Page 14 CONTROLS CAUTION Engage parking brake before 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: [...]

  • Page 15

    Page 15 CONTROLS: 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 le[...]

  • Page 16

    Page 16 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 an[...]

  • Page 17

    Page 17 OPERA TION INSTRUCTIONS Safe and successful operation 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, "l[...]

  • Page 18

    Page 18 OPERA TION INSTRUCTIONS 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 [...]

  • Page 19

    Page 19 OPERA TION INSTRUCTIONS 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 r[...]

  • Page 20

    Page 20 OPERA TION 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[...]

  • Page 21

    Page 21 OPERA TION 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 e[...]

  • Page 22

    Page 22 OPERA TION 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. 1. Set engine speed control to the wide open or full setting. 2. Do Not Attempt To Cut Gra[...]

  • Page 23

    Page 23 CARE AND MAINTENANCE This portion of the owners manual deals with normal service items which can be performed by the owner. Please remember that if you are in doubt as to the correct service procedures to be followed, these and other service situations can be handled by a Dixon ZTR dealer who is familiar with the service of your mower. MAIN[...]

  • Page 24

    Page 24 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. Note: Be sure blade is center on pilot before tightening nut to [...]

  • Page 25

    Page 25 CARE AND MAINTENANCE BELT TENSION: 36" DECK: MOWER DECK DRIVE BELT: P/N 1300 Manual adjustment. Refer to illustration below. 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" DE[...]

  • Page 26

    Page 26 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 no[...]

  • Page 27

    Page 27 CARE AND MAINTENANCE NEUTRAL ADJUSTMENT  1. Stop the engine, engage parking brake, and raise rear of frame with jack or blocks so that rear tires do not contact the ground. 2. Swing out the control levers, start the engine and release the parking brake. 3. Raise the seat to access hydro control linkage. If right wheel creeps, adjust righ[...]

  • Page 28

    Page 28 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 bo[...]

  • Page 29

    Page 29 CARE AND MAINTENANCE 36" DECK REMOVAL 1. Place cut height lever in lowest cut position. 2. Loosen nut on belt idler shock mount until belt can be removed from electric clutch pulley on the bottom of the engine. 3. Remove hair pin cotter and washer from one end of deck support cross shaft. Note location of remaining shim washers used be[...]

  • Page 30

    Page 30 42" and 50" 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 pla[...]

  • Page 31

    Page 31 CARE AND MAINTENANCE CHANGING THE ENGINE OIL: 1. The "snap lock" oil drain valve is located on the left side of the engine crankcase. 2. Place a suitable container under the drain valve. The fitting of a short piece of hose to the valve will help direct the oil. 3. Push the valve body in and twist to clear the detent notch. 4. Pul[...]

  • Page 32

    Page 32 OIL FILL: 1. Push the valve body in and twist into the detent notch. 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: Oil changes require replacement of the oil filters. These filters can be obtained from your authorized engin[...]

  • Page 33

    Page 33 CARE AND MAINTENANCE WHEELS AND TIRES: Correct tire pressure is important for correct operation of mower. Front Tires 11 X 4.00 X 5 16-21 PSI Rear Tires 18 X 8.50 X 8 8-14 PSI NOTE: Check lug nuts periodically for tightness. ELECTRICAL SYSTEMS: Keep all connections clean and tight. CLEANING THE MOWER: Wash mower periodically. Clean above an[...]

  • Page 34

    Page 34 ST ANDARD SER VICE P ARTS LIST 36" DECK: BLADES: Standard: P/N 1324 Hi-Lift: P/N 1351 Right Side P/N 1352 Left Side BELTS: Engine To Mower Deck: P/N 1300 Engine To Transmission: P/N 5768 42" DECK: BLADES: Standard Hi-Lift: P/N 8688 Lo-Lift: P/N 6236 BELTS: Engine To Mower Deck: P/N 5861 Serpentine Belt: P/N 6109 Engine To Transmis[...]

  • Page 35

    Page 35 Poor cut quality Poor cut quality Poor cut quality Poor cut quality Poor cut quality Poor cut quality Poor cut quality Poor cut quality TROUBLESHOOTING MOWER CUT QUALITY: There are many variables that can effect the cut quality of any riding mower. Type and conditions of grass, cut height setting, engine RPM and ground speed are some of the[...]

  • Page 36

    Page 36 Mower creeps in neutral position Mower pulls to one side or the other Loss of power and speed on both sides . Drive system functions on one side only DRIVE SYSTEM: TROUBLESHOOTING Refer to page 24 for procedure or consult your dealer for repair Refer to page 23 for procedure Replace belt Replace spring Remove cause of seizure and lubricate [...]

  • Page 37

    Page 37 ELECTRICAL SYSTEM: Starter will not turn engine over Starter will not turn engine over Battery discharge Battery discharge Battery discharge TROUBLESHOOTING Push button to reset Consult your dealer for repair Charge battery Tighten or replace as required Have electrical system checked by your dealer Increase engine RPM Contact your dealer f[...]

  • Page 38

    DATE PURCHASED MOWER MODEL NUMBER MOWER SERIAL NUMBER PURCHASED FROM OWNER INFORMA TION DATE OIL CHANGED: DATE ENGINE TUNED: DM- Address Name DIXON INDUSTRIES, INC. A BLOUNT International Inc. Co. PO BOX 1569 COFFEYVILLE KS 67337 0945 316 251 2000 FAX 316 251 4117[...]

  • Page 39

    ® Dixon and ZTR are registered trademarks of Dixon Industries, Inc. 4500 Series Part No. 5863-0798 DIXON INDUSTRIES, INC. A BLOUNT International Inc. Co. PO BOX 1569 COFFEYVILLE KS 67337 0945 316 251 2000 The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive ha[...]