Dixon Lawn Mower ZTR 4515B User Guide

1999 Operator's Manual  
4500  
SERIES  
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INDEX  
SAFETY .................................................................Pages 2 - 7  
WARRANTYPOLICY..............................................Page  
SPECIFICATIONS..................................................Page  
SEAT ADJUSTMENT.............................................Page  
8
9
10  
CONTROLS ...........................................................Pages 11 - 14  
OPERATIONINSTRUCTIONS ................................Pages 15 - 20  
CARE AND MAINTENANCE..................................Pages 21 - 31  
STANDARD PARTS LIST ......................................Page  
32  
TROUBLESHOOTING ............................................Pages 33 - 35  
4500 Series  
Part No. 5863-0798  
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SAFETY  
RIDINGLAWNMOWERS,IFIMPROPERLYOPERATED,  
CANCAUSESERIOUSINJURYORDEATH  
The most common causes of injury to the operator or bystander...  
BLADECONTACT  
TIP-OVER  
BACK-OVER  
...read and understand this manual to prevent injuries.  
Page 4  
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SAFETY  
SAFETY SYMBOLS  
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  
which, if not avoided, could result in death or  
serious injury.  
Caution  
indicates a potentially hazardous situation  
which, if not avoided, may result in minor or  
moderate injury. It may also be used to alert  
againstunsafepractices.  
Page 5  
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SAFETY  
This cutting mower is capable of amputating hands & feet,  
and throwing objects.  
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.  
• Nevercarrypassengers.  
• 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.  
• 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 & unloading.  
The Engine Exhaust from this product contains chemicals known to the  
State of California to cause cancer, birth defects or other reproductive harm.  
WARNING:  
Page 6  
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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.  
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 gradually 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.  
Page 7  
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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.  
Page 8  
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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 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 building where there is an open  
flame.  
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.  
Grass catcher components are subject to wear, damage, and deterioration, which  
could expose moving parts or allow objects to be thrown. Frequently check  
components and 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.  
Check to assure that the drive chains are properly adjusted. A loose chain may come  
off causing loss of control.  
Page 9  
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DIXON PROTECTION PLUS TWO YEAR LIMITED WARRANTY POLICY  
This warranty policy applies to all ZTR 4500 Series mowers purchased on or after September 1, 1997.  
WARRANTY: The Dixon ProtectionPlusWarrantytermisforaperiodoftwo(2)years fromdateofpurchase. DIXON  
ZTRMOWERSAREWARRANTEDAGAINSTDEFECTSINMATERIALSANDWORKMANSHIPANDPROVIDESFOR  
REPLACEMENTORREPAIROFPARTSINCLUDINGLABORCOSTS.THISWARRANTYISSUBJECTTOTHE  
FOLLOWINGCONDITIONSANDLIMITATIONS:  
1.  
2.  
Warranty applies only to original retail purchaser of new and unused mowers and accessories.  
AllDixonwarrantymustbeaccomplishedbyauthorizedDixondealersandinaccordancewithDixon  
warranty policy and allowances. All warranty claims must be approved by Dixon Industries, Inc.  
3.  
Mowers or accessories used for commercial applications are warranted for 90 days from date of  
purchase. Commercial application is any use other than, or in addition to, mowing at owner's primary  
placeofresidence.  
4.  
5.  
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.  
6.  
7.  
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.  
VOIDSALLWARRANTY.  
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) Routinemaintenanceoradjustments.  
(c) Belts / chains / sprockets / cutting blades.  
(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.  
8.  
There is no other express warranty. Implied warranties, including those of merchantability 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.  
WARRANTYVALIDATION:Atthetimeofsale,sellingdealermustrevieweachportionofthiswarrantydocument,completethe  
informationsectionbelow,securecustomer'ssignatureandsendcopytoDixonIndustries,Inc.  
DM-  
DATEOFPURCHASE_______________________________Model____________________ S/N______________________  
(Owner'sName)  
(Address)  
(Dealership)  
(Address)  
(Owner'sSignature)  
Page 10  
(Dealer'sSignature)  
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SPECIFICATIONS  
Models ZTR 4515B and 4516K  
CHASSIS:  
BODY:  
Twin 12 gauge side frames and 7 gauge transmission and engine base plate.  
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 Width  
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" to 4" via 7 position lift handle.  
Electric clutch.  
BLADEDRIVE:  
TRANSMISSION:  
ENGINE:  
Each rear wheel is independently driven by a HydroGear IZT hydrostatic drive.  
Model 4515B:  
15HP Vanguard Briggs & Stratton, 4-Cycle, Single Cylinder, Overhead  
Valve, Air-Cooled, Gasoline, Vertical Shaft With Cast Iron Cylinder  
Sleeve, Oil Pump With Integral Oil Filter.  
Model 4516K:  
16 HP Kohler Command 16, 4-Cycle, Single Cylinder, Overhead Valve,  
Air-Cooled, Gasoline, Pressure Lubricated, With Oil Filter, Vertical Shaft,  
Aluminum Head and Block with Cast-Iron Cylinder Liner. Smart Spark  
Ignition.  
STARTING SYSTEM:  
TIRES:  
Electric by key switch operation with safety interlock blade drive.  
Front  
Rear  
11 X 4.00 X 5 ribbed tread.  
18 X 8.50 X 8 Multi-Trac  
RECOMMENDED  
TIRE PRESSURE:  
Front  
Rear  
16-21 lbs.  
8-14 lbs.  
CAPACITIES:  
DIMENSIONS:  
Fuel  
Engine  
2.7 gallons total.  
Briggs & Stratton - 1.50 quarts oil.  
Kohler - 2 quarts oil with filter.  
Width  
44" Maximum Track Width  
42" to top edge of seat.  
72" hitch tab to front bumper.  
Height  
Length  
Weight  
Power Unit:  
w/36" Deck:  
w/42" Deck:  
463 lbs.  
544 lbs.  
541 lbs.  
NOTE:  
Additionalinformationprovidedinserviceinstructionsundertheindividualcomponent.  
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE  
Page 11  
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SEAT ADJUSTMENT INSTRUCTIONS  
1.  
2.  
3.  
Place parking brake in ON position. (Pull brake lever up)  
Raise and push seat assembly forward.  
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 assembly and upper body rearward to closed position.  
Page 12  
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CONTROLS  
CONTROL  
LEVERS  
FRONT OF  
MACHINE  
IGNITION  
SWITCH  
THROTTLE  
CONTROL  
BLADE  
DRIVE  
SWITCH  
DECK HEIGHT  
ADJUSTMENT  
LEVER  
CIRCUIT  
BREAKER  
LIGHT  
SWITCH  
PARKING  
BRAKE  
LEVER  
Page 13  
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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.  
CAUTION  
Engage parking brake before  
starting engine.  
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.  
Page 14  
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CONTROLS:  
(left turn opposite)  
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 lever rearward of the right lever.  
To turn "square corners" move lever of desired direction to neutral.  
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, release levers to  
neutral, set parking brake. Park only on level surfaces.  
THROTTLE CONTROL:  
Located on control panel to operator's right.  
Throttle control for engine speed.  
Choke for engine starting.  
Throttle Control should be set to the MAXIMUM or wide open setting to insure adequate  
cooling of the engine and to maintain mower deck blade speed while mowing.  
Page 15  
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CONTROLS:  
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.  
CIRCUITBREAKER:  
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.  
MOWER DECK CUT HEIGHT LIFT LEVER:  
Located to the left of operator.  
Controlsthecuttingheight.  
Sevenpositionsofadjustment.  
Move lever in and forward to lower.  
Move lever in and back to raise.  
NOTE: Always use high for transport.  
Page 16  
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OPERATIONINSTRUCTIONS  
Safeandsuccessfuloperationwilldependupontheoperatorhavingthecorrect knowledgeofall  
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.  
Soundjudgementbytheoperatorwillpreventaccidents.  
Drink/Cup Holder located on the left rear fender is for transport or carrying only!  
Mower usage requires that both hands be free to control individual levers.  
DO NOT ATTEMPT operation of mower with any type  
of container or other object in either hand.  
Towing  
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 on this mower.  
BEFORE OPERATING MOWER:  
1. Read engine manufacturer's operating and maintenance  
instructions.  
2. Read and observe all safety instructions on your mower and in  
the manual.  
3. Check engine oil.  
4. Be sure gas cap is in place.  
5. Be sure parking brake is on.  
6. Be sure mower blade drive is off.  
7. Know how to stop engine. (Turn key to off position)  
Page 17  
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OPERATIONINSTRUCTIONS  
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.  
a) Put parking brake in ON position  
b) Swing out control levers  
c) Engage blade drive switch  
BLADE DRIVE SWITCH TEST:  
SEAT SWITCH TEST:  
d) Turn ignition switch to START  
Engine should not turn over or attempt to start.  
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  
e) Disengage blade drive  
f) with engine running, put parking brake  
in OFF position  
g) Swing levers in  
h) Engage blade drive  
i) Raise weight 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 ZTR Dealer  
Page 18  
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OPERATIONINSTRUCTIONS  
Engage parking brake before starting engine.  
CAUTION  
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 return to  
"Run" position.  
4. Move throttle from "Choke" to desired speed position.  
5. Release parking brake.  
6. Swing levers in.  
7. Operate the mower per the "CONTROL" instructions  
on page 12.  
NOTE: While mowing 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.  
Page 19  
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OPERATIONINSTRUCTIONS  
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.  
2.  
Set the engine speed control to the wide open or full setting.  
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.  
4.  
5.  
6.  
7.  
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.  
Do Not Attempt To Cut Grass When It Is Wet. Mulching performance will be very poor under  
wet grass conditions.  
Maintain A Sharp Blade Throughout The Cutting Season. This is very important. Optimal  
mulching performance cannot be obtained with a dull or nicked up blade.  
Keep The Underside Of The Mower Deck Clean. Remove all grass and dirt buildup 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:  
1.  
2.  
3.  
4.  
5.  
6.  
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 cutting a full swath with each pass.  
Mow across the marginal areas a second time.  
CUT HIGH - MOW OFTEN!  
Page 20  
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OPERATIONINSTRUCTIONS  
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.  
3.  
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.  
4.  
5.  
6.  
7.  
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.  
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 Blades Throughout The Cutting Season. Some grass catching attachments  
require "Hi-Lift" blades.  
Operate the mower at a slower ground speed than when mowing without a grass catching  
attachment.  
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  
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 bags.  
Page 21  
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OPERATIONINSTRUCTIONS  
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 deflector is properly installed  
on the discharge chute.  
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 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 Blades Throughout The Cutting Season.  
GRASS HEIGHT SUGGESTIONS:  
Correct mowing height can reduce weeds and disease by 50 to 80%  
The following grass cut heights are based on 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  
Zoysia  
Blue Grass  
Fescue Blends  
St. Augustine (Mid South)  
St. Augustine (Deep South)  
Tifton Bermuda  
2" - 2 1/2"  
1 1/2" - 3"  
1 1/2" - 3"  
1 1/2" - 2"  
3" - 4"  
1 1/2"  
Centipede  
Common Bermuda  
Bahia/Argentina/Pensacola  
1 1/2" - 2"  
1 1/2" - 2"  
2"  
Page 22  
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CARE AND MAINTENANCE  
Thisportionoftheownersmanualdealswithnormalserviceitemswhichcanbeperformedbytheowner.  
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.  
MAINTENANCE SCHEDULE:  
To insure a long and trouble free service life of all components, a regular and thorough  
maintenance schedule should be followed. The following items should be checked after  
the first (10) hours of operation and on a weekly basis, or each (40) hours of use:  
1.  
2.  
3.  
4.  
5.  
6.  
Drive system, belts and controls.  
Mower deck belts.  
Tire pressures.  
Tightness of all nuts and bolts.  
Battery fluid level.  
Engine Oil.  
Before performing any maintenance, shut off engine, allow to cool.  
CAUTION  
ENGINE:  
For engine operating and maintenance information, refer to the engine operating and  
maintenance instructions furnished by the engine manufacturer, supplied with each  
mower.  
BATTERY: Check the fluid in the battery at frequent intervals.  
Keep fluid level above the plates in each cell, using distilled water.  
OFF-SEASON BATTERY STORAGE:  
Identify each cable so cables can be reconnected to correct terminals.  
Disconnect cables from terminals  
ALWAYS disconnect ground cable first and reconnect last  
Charge battery.  
DO NOT remove battery from mower.  
Clean top of battery and terminals with baking soda and water.  
Page 23  
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CARE AND MAINTENANCE  
MOWERBLADEMAINTENANCE:  
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.  
Wear heavy, thick gloves when holding onto mower blade,  
CAUTION  
avoid the sharp edge of the blade.  
Note: Be sure blade is center on pilot before tightening nut to 60 ft. lbs. torque.  
Page 24  
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CARE AND MAINTENANCE  
BELT TENSION:  
36" DECK:  
MOWER DECK DRIVE BELT:  
P/N 1300  
P/N 6109  
Manual adjustment. Refer to illustration below.  
42" DECK:  
MOWER DECK SERPENTINE BELT:  
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 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.  
Page 25  
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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. Ifonesidenowdrivesslightlyfasterthantheother,adjustleverstopwasherP/N5760  
on that side to reduce forward range of control lever. If levers are now uneven at top  
speed, loosencontrollevermountingnut. Rotatelevertobeevenwithothersideand  
tighten nut.  
Page 26  
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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 right side linkage, and  
vice-versa. Use procedure below:  
a. Loosen, but do not remove, the bolt in the control tube P/N 5540.  
b. Loosen Jam nuts on ends of the  
coupler P/N 7736.  
c. Ifrightwheeliscreepingforward,  
turn coupler counter clockwise  
until neutral is achieved  
(clockwise for left side). If right  
wheeliscreepingbackward,turn  
coupler clockwise until neutral is  
achieved (counterclockwise for  
left side).  
d. Tightenjamnutsagainstcoupler.  
e. Tighten bolt in control tube.  
4. Lower seat, release parking brake, and swing control levers in. If wheel creeps, repeat steps 3a & 3e.  
5. Stop engine and remove rear of machine  
from jack or blocks.  
6. 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,  
loosencontrollevermountingnut. Rotate  
lever to be even with other side and  
tighten nut.  
Page 27  
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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.  
Page 28  
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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 between chassis and mower deck  
plates. Slide shaft from chassis and mower deck.  
4. Remove hair pin cotter and washer from each deck L-rod. Remove L-rods from  
lift arms. At this point, deck will drop down.  
5. Carefully raise and support front of chassis. Slide mower deck to either side for  
removal. (Reverse procedure to reinstall deck assembly)  
Page 29  
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CARE AND MAINTENANCE  
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  
plates. Slide shaft from chassis and mower deck.  
4. Remove hair pin cotter and washer from each deck L-rod. Remove L-rods from  
lift arms. At this point, deck will drop down.  
5. 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 groves of all pulleys and that belt idler is applying tension to the  
back side of the belt.  
Page 30  
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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 "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. Pulling the valve body outward will start the flow of oil.  
NOTE: Refer to engine manufacturers recommendations for frequency of oil changes.  
Briggs & Stratton  
Kohler  
PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS.  
-PROTECT YOUR ENVIRONMENT-  
Page 31  
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OIL FILL:  
1. Push the valve body  
in and twist into the  
detent notch.  
Closed  
Open  
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 engine dealer.  
The use of any other oil filter may cause damage to the engine.  
Briggs & Stratton Oil Filter: P/N 492 932  
Kohler Oil Filter: P/N 52 050 02  
PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS.  
-PROTECT YOUR ENVIRONMENT-  
LUBRICATION:  
CHASSIS:  
Number of grease zerks used:  
(6) for 36"  
(7) for 42"  
(7) for 50"  
LOCATIONS:  
(1) each front wheel caster tube and each front wheel hub.  
(1) each mower deck hub.  
SERVICE INTERVALS:  
Every 50 hours of operation  
RECOMMENDEDGREASE:  
Name brand wheel bearing or multi-purpose grease  
Lubricate each front wheel to allow even distribution of grease  
within the wheel, rotate or spin each front wheel after (3) pumps  
of the grease gun. Repeat process until the appearance of  
grease is noted completely around each caster axle.  
Page 32  
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CARE AND MAINTENANCE  
WHEELS AND TIRES:  
Correct tire pressure is important for correct operation of  
mower.  
Front Tires  
Rear Tires  
11 X 4.00 X 5  
18 X 8.50 X 8  
16-21 PSI  
8-14 PSI  
NOTE: Check lug nuts periodically for tightness.  
ELECTRICAL SYSTEMS:  
CLEANING THE MOWER:  
Keep all connections clean and tight.  
Wash mower periodically.  
Clean above and below deck.  
NOTE:  
Allowmowertocoolbeforewashing. Ifbearingsare  
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, it will  
begin with DM.  
WARRANTY:  
Refer to Warranty Registration Form (P/N 5859).  
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.  
Page 33  
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STANDARD SERVICE PARTS LIST  
36" DECK:  
42" DECK:  
50" DECK"  
BLADES:  
BELTS:  
Standard:  
Hi-Lift:  
P/N 1324  
P/N 1351 Right Side  
P/N 1352 Left Side  
Engine To Mower Deck: P/N 1300  
Engine To Transmission: P/N 5768  
BLADES:  
BELTS:  
StandardHi-Lift:  
Lo-Lift:  
P/N 8688  
P/N 6236  
Engine To Mower Deck: P/N 5861  
Serpentine Belt: P/N 6109  
Engine To Transmission: P/N 5768  
BLADES:  
Standard Hi-Lift:  
Lo-Lift:  
P/N 9444  
P/N 9443  
BELTS:  
Engine To Mower Deck: P/N 7174  
Serpentine Belt: P/N 1300  
Engine To Transmission: P/N 5768  
BRIGGS & STRATTON FILTER PART NUMBERS:  
Please refer to Briggs & Stratton Engine Operators Manual for correct service intervals for engine oil  
changes and air filter maintenance.  
Protect your engine investment, use only original equipment filters.  
Precleaner Foam Element  
Air Filter Cartridge:  
Engine Oil Filter:  
P/N 272 403  
P/N 493 909  
P/N 492 932  
KOHLER FILTER PART NUMBERS:  
Please 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 Cartridge:  
Pre-Cleaner:  
Engine Oil Filter:  
P/N 12 08 310  
P/N 12 08 312  
P/N 52 050 02  
Page 34  
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TROUBLESHOOTING  
MOWER CUT QUALITY:  
There are many variables that can effect the cut quality of any riding mower. Type and  
conditionsofgrass, cutheightsetting, engineRPMandgroundspeedaresomeofthevariables  
that interact creating differences in cut quality. Examination of one or more of the above will  
generally produce a quality cut.  
The Troubleshooting Chart suggests practices and adjustments that may be helpful in  
improving cut quality. Your Dixon ZTR dealer is also available to provide assistance to you.  
SITUATION  
CAUSES  
REMEDY  
Poorcutquality  
Groundspeed  
Reduce mowing speed  
Poor cut quality  
Incorrect engine to  
mower deck belt  
Refer to page 31 for part numbers  
Poor cut quality  
Poor cut quality  
Poor cut quality  
Poor cut quality  
Engine RPM too low  
Dull or bent blade  
Increase engine RPM to maximum  
Sharpen or replace as required  
Un-level mower deck  
Refer to page 25 for deck leveling  
procedure  
Grass buildup under  
mower deck  
Clean out underside of mower deck  
Poor cut quality  
Poor cut quality  
Improper blades  
Refer to page 31 for part numbers  
Uneven tire pressures  
Refer to page 30 for correct tire  
pressures  
Page 35  
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TROUBLESHOOTING  
DRIVE SYSTEM:  
SITUATION  
CAUSES  
REMEDY  
Mower creeps in  
neutral position  
Neutraladjustment  
Refer to page 24 for procedure or consult  
your dealer for repair  
Mower pulls to one  
side or the other  
Forward travel speed  
adjustment  
Refer to page 23 for procedure  
Loss of power and  
speed on both sides  
.
Incorrect or worn drive  
belt  
Replace belt  
Spring on idler arm  
missing or broken  
Replace spring  
Idler arm will not pivot  
Internal malfunction  
Remove cause of seizure and lubricate  
Consult your dealer for repairs  
Drive system  
Incorrect or worn drive  
Replace belt  
functions on one side belt  
only  
Spring on idler arm  
Replace spring  
missing or broken  
Idler arm will not pivot  
Remove cause of seizure and lubricate  
Consult you dealer for repairs  
Internal malfunction  
Page 36  
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TROUBLESHOOTING  
ELECTRICAL SYSTEM:  
SITUATION  
CAUSES  
REMEDY  
Starterwillnot  
Circuit breaker  
Pushbuttontoreset  
turn engine over  
disengaged  
Consult your dealer for repair  
Starter will not  
Dead Battery  
Charge battery  
turn engine over  
Battery discharge  
Poor connections on  
battery  
Tighten or replace as required  
Battery water low  
Wrong battery installed  
in mower  
Battery discharge  
Battery discharge  
Engine electrical system Have electrical system checked by your  
not functioning correctly dealer  
Engine not being  
Increase engine RPM  
operated at full throttle  
Contact your dealer for information  
NOTE: Electricalsystemfailuresaregenerallysimpleinnature,alwayschecktheobviousfirst  
and then move onto the more complicated parts used.  
Poorbatteryservice, looseconnections, corrosion, frayedorbrokenwiring, aremore  
likely than component failure.  
Page 37  
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OWNER  
INFORMATION  
DIXONINDUSTRIES,INC.  
A BLOUNT International Inc. Co.  
PO BOX 1569  
COFFEYVILLE KS 67337 0945  
316 251 2000  
FAX 316 251 4117  
DATE PURCHASED  
MOWER MODEL NUMBER  
MOWER SERIAL NUMBER  
DM-  
PURCHASED FROM  
Name  
Address  
DATE OIL CHANGED:  
DATE ENGINE TUNED:  
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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.  
PO BOX 1569  
4500 Series  
Part No. 5863-0798  
COFFEYVILLE KS 67337 0945  
316 251 2000  
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