Dixon ZTR 2002 Operator's Manual
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Dixon ZTR 2002 Operator's Manual

Dixon ZTR 2002 Operator's Manual

4500 series
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4500 SERIES
ZTR
®
2002

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Summary of Contents for Dixon ZTR 2002

  • Page 1 4500 SERIES ® 2002...
  • 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.

  • Page 3: Table Of Contents

    INDEX Page Safety........4-11 Warranty Policy.

  • Page 4: Safety

    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.

  • Page 5: Safety Alert Symbol

    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...

  • Page 6: General Operation

    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.
  • Page 7 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.

  • Page 8: Slope Operation

    If you cannot back up the slope or if you feel uneasy on it, do not mow it! • Mow across the slope with your Dixon ZTR - never up or down. • Remove obstacles such as rocks, tree limbs, etc.
  • Page 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. •...
  • Page 10 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.

  • Page 11: Safety

    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.

  • Page 12: Warranty Policy

    Fax 620-251-4117 DIXON LIMITED WARRANTY POLICY - 4500 Series WARRANTY: Home Owner Application: This Dixon Warranty term is for a period of two (2) years from date of purchase. Commercial Application: Dixon mowers used for commercial application are warranted for 90 days from the date of purchase. Commercial use is specified as use other than, or in addition to, mowing at owner’s primary place of residence.

  • Page 13: Specifications

    SPECIFICATIONS Model ZTR 4515B, 4516K & 4518K 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. Front body contains access panel for battery service. MOWER DECK: 42”...

  • Page 14: Seat Adjustment Instructions

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

  • Page 15: Controls

    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: •...

  • Page 16: Parking Brake

    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.

  • Page 17: Controls

    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 : 4515B & 4516K • Protection of the electrical system is by (1) 15 amp circuit breaker.

  • Page 18: Operation Instructions

    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.
  • Page 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): Rotate hydro release lever (on top of right hydro) until it is held in Place by the by-pass keeper.

  • Page 20: Testing Of Safety Interlock Systems

    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...

  • Page 21: Testing Of Safety Interlock Systems

    Leave levers swung out and parking brake ON c) Engage blade drive d) Raise slightly off seat ENGINE SHOULD STOP! If Any Safety Check FAILS, Do Not Operate NOTE: The Mower until the system has been checked and repaired by an Authorized Dixon Dealer.
  • Page 22 OPERATION INSTRUCTIONS CAUTION Engage parking brake before starting engine. STARTING INSTRUCTIONS (4515B & 4516K): 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”...
  • Page 23 OPERATION INSTRUCTIONS CAUTION Engage parking brake before starting engine. STARTING INSTRUCTIONS (4518K): 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.

  • Page 24: Side Discharge Of The Clippings

    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. Be sure that the deflector is properly CAUTION installed on the discharge chute.
  • Page 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.

  • Page 26: Mowing With A Mulching Attachment

    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.
  • Page 27 OPERATION INSTRUCTIONS MOWING WITH A MULCHING ATTACHMENT continued): 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.

  • Page 28: Mowing With A Grass Catcher Attachment

    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. Set engine speed control to the wide open or full setting. Do Not Attempt To Cut Grass When It Is Wet.

  • Page 29: Operation Instructions

    OPERATION INSTRUCTIONS MOWING WITH A GRASS CATCHER ATTACHMENT (continued): 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.

  • Page 30: Care & Maintenance

    CARE AND MAINTENANCE CAUTION CAUTION CAUTION CAUTION CAUTION Before perf ore perf ore perfor or or or orming an ore perf ming an ming an ming any maintenance y maintenance y maintenance, tur y maintenance , tur , turn off engine , tur n off engine n off engine, , , , ,...

  • Page 31: Care And Maintenance

    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 CAUTION poisonous and corrosive.

  • Page 32: Cutter Blade Maintenance

    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.

  • Page 33: Belt Tension

    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.

  • Page 34: Neutral Adjustment

    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. Stop the engine, engage parking brake and raise rear of frame with jack or blocks so that rear tires do not contact the ground.
  • Page 35 CARE AND MAINTENANCE NEUTRAL ADJUSTMENT (continued) Lower seat, release parking brake and swing control levers in. If wheel creeps, repeat steps 3a & 3e. 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.
  • Page 36 CARE AND MAINTENANCE FORWARD TRAVEL SPEED ADJUSTMENT Drive machine until hydrostats have warmed up. Drive on a smooth, level surface 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.

  • Page 37: Mower Deck Leveling Procedure

    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.

  • Page 38: Deck Removal

    CARE AND MAINTENANCE DECK REMOVAL: 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. Remove hair pin cotter and washer from one end of deck support cross shaft.

  • Page 39: Changing The Engine Oil

    CARE AND MAINTENANCE HOT oil may cause burns. Allow engine to cool before CAUTION draining oil. CHANGING THE ENGINE OIL: The “Dapco” oil drain valve is located on the left side of the engine crankcase (Model 4515B & 4518K) and on the right side of the engine crankcase (Model 4516K).
  • Page 40 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.

  • Page 41: Brake System

    CARE AND MAINTENANCE LUBRICATION: CHASSIS: (7) grease zerks used on 42” & 50” LOCATIONS: (1) each front wheel caster & front wheel hub (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:...

  • Page 42: Care & Maintenance

    The serial number is located on frame at rear of engine. WARRANTY: Refer to Warranty Registration Form (P/N 8288). 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...

  • Page 43: Standard Service Parts List

    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...

  • Page 44: Troubleshooting

    TROUBLESHOOTING 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...
  • Page 45 TROUBLESHOOTING 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)
  • Page 46 NOTES...
  • Page 47 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:...
  • Page 48 ARNING: ARNING: ARNING: to the State of California to cause cancer, birth defects or other reproductive harm. Dixon® and ZTR® are registered trademarks of Dixon Industries, Inc. DIXON INDUSTRIES, INC. a BLOUNT International Inc. Co. 4500 Series P.O. Box 1569 Coffeyville, Ks 67337-0945 4515B, 4516K &...

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