Dixon Zeeter Classic ZTR 2002 User manual

ZTR®
OPERATOR’S MANUAL
4500 SERIES
2002

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 manual applies to all
Dixon®ZTR®4500 Series Mowers. Your Dixon dealer
will gladly answer any questions.
See your dealer for warranty service, parts and repairs.

3
INDEX
Page
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Seat Adjustment Instructions. . . . . . . . . . . . . . . . . . . . . . . . .14
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-17
Operation Instructions. . . . . . . . . . . . . . . . . . . 18-29
Care & Maintenance. . . . . . . . . . . . . . . . . . . . . .30-42
Standard Service Parts List. . . . . . . . . . . . . . . . . . . .43
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .44-45
4500 Series
Part No. 13088-1001

4
RIDING LAWN MOWERS,
IFIMPROPERLYOPERATED,
CAN CAUSE SERIOUS INJURY OR DEATH.
The most common causes of injury to the operator or bystander...
...readandunderstandthismanualtopreventinjuries.
BLADECONTACT
TIP OVER
RUNOVER
BACK OVER
SAFETY

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
serious injury.
CAUTION
(highlighted in yellow)
indicates a potentially
hazardous situation which, if not
avoided, may result in minor or
moderate injury. It may also be used
to alert against unsafe practices.
Follow recommended safety precautions
and safe operating practices.
SAFETY

6
Failure to observe the following safety
instructions could result in serious injury or death.
GENERALOPERATION:
•Read, understand, and follow all instructions in the
manual and onthemower 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.
•Donotoperatethemowerwithouteithertheentire
grass catcher or the deflector in place.
•Slow down before turning.
•Neverleavearunningmower unattended. Always turn
off blades, set parking brake, stop engine and remove
keybeforedismounting.
SAFETY

7
GENERALOPERATION(continued) :
•Turn off blades when not mowing.
•Stopenginebeforeremovinggrasscatcheror
unclogging chute.
•Mow only in daylight or good artificial light.
•Donot operate themowerwhileunderthe influence
of alcohol or drugs.
•Watchfortraffic when operatingnearorcrossing
roadways.
•Useextra care whenloadingorunloadingthe mower
into a trailer or truck. Do not ride the mower when
loadingandunloading.
•Always wear safety goggles or safety glasses with
side shields when operating mower.
•Dataindicates that operators,age60 years andabove,
are involved inalargepercentageof riding mower-
related injuries. Theseoperatorsshould evaluatetheir
ability to operate the riding mower safely enough to
protectthemselves and othersfromseriousinjury.
•Follow the manufacturer’s recommendation for wheel
weights and counterweights.
•Maintain/replace safety &instructionlabels as needed.
WARNING:
TheengineexhaustfromthisproductcontainschemicalsknowntotheStateof
Californiatocausecancer,birth defectsorother reproductiveharm.
SAFETY

8
SLOPE OPERATION:
Slopesareamajorfactorrelatedtoloss-of-controlandtip-overaccidents,
whichcanresultinsevereinjuryordeath.
Allslopes require extra caution.
If you cannot back up the slope or if you feel uneasy on it,
do not mow it!
DO •Mowacross theslope withyour DixonZTR -neverup or down.
•Removeobstaclessuchasrocks,treelimbs, etc.
•Watchfor holes,ruts orbumps. Uneventerrain couldoverturnthe
mower. Tallgrass canhide obstacles.
•Use slow speed. Tires may lose traction on slopes even though the
driveand/or brakesare functioningproperly.
•Useextracare withgrass catchers orother attachments.These can
change thestability ofthe mower.
•Keep all movement on the slopes slow and gradual. Do not make
sudden changes in speed or direction.
•Avoidstartingor stoppingon aslope. If tireslose traction,disengage
the blades and proceed slowly down the slope.
•Iffront 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
graduallydownhill, if possible.
• Do not mow near drop-offs, ditches, or embankments. The mower
could suddenlyturn overifa wheelisover theedgeof acliffor ditch,
or if an edge caves in.
• Do not mow onwet grass. Reducedtraction couldcause sliding.
• Do not try to stabilize the mower by putting your foot on the ground.
• Do not use grass catcher on steep slopes.
SAFETY

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.
• Keepchildren outofthe mowingareaand under
the watchful care of another responsible adult.
•Be alert and turn mower off if a child enters the
area.
•Beforeand during backing,lookBEHINDand
DOWN for small children.
•Nevercarry children. They mayfalloffandbe
seriously injured or interfere with safe mower
operation.
•Neverallowchildrentooperate the mower.
•Useextracarewhenapproachingblindcorners,
shrubs, trees, or other objects that may obscure
vision.

10
SERVICE:
•Use extra care in handling gasoline and other fuels.
They are flammable and vapors are explosive.
Useonlyanapprovedcontainer.
Never remove fuel cap or add fuel with engine
running. Allow engine to cool before refueling.
Donotsmoke whilerefueling.
Neverrefuelthemowerindoors.
Never store the mower or fuel container
inside a building where there is an open
flame.
If fuel is spilled on clothing, change clothing
immediately.
To prevent fire and explosion caused by static
electricity:
Never fill containers inside a vehicle or on a
truck or trailer bed with a plastic liner. Always
place containers on the ground away from
your vehicle before filling.
Whenpractical,removefuel-poweredequipment
from the truck or trailer and refuel it on the
ground. If this is not possible, then refuel such
equipmentonatrailerwithaportablecontainer,
ratherthanfromafueldispensernozzle.
If a fuel dispenser nozzle must be used, keep the
nozzle in contact with the rim of the fuel tank or
containeropeningatalltimesuntilfuelingis
complete. Do not use a nozzle lock-open device.
SAFETY

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 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 unless otherwise specified.
•Grass catcher components are subject to wear,
damage and deterioration, which could expose moving
parts or allow objects to be thrown. Frequently check
components & 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.
SAFETY

12
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.
DIXONZTRMOWERSAREWARRANTEDAGAINSTDEFECTSINMATERIALS
ANDWORKMANSHIPAND PROVIDESFOR REPLACEMENTOR REPAIROFPARTS
INCLUDINGLABOR COSTS. THISWARRANTYIS SUBJECTTOTHE FOLLOWING
CONDITIONS ANDLIMITATIONS:
1. Warranty applies only to original retail purchaser of new and unused mowers and accessories.
2. All Dixon warranty must be accomplished by authorized Dixon dealers & in accordance with
Dixon warranty policy and allowances. All warranty claims must be approved by Dixon Industries,
Inc.
3. Battery warranty: Limited to 90 days from date of purchase.
4. Accessories Warranty (Grass Catchers, Snow Blades, Covers, etc.): Limited to 90 days from
date of purchase.
5. 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.
VOIDS ALL WARRANTY.
6. 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. Routine maintenance or adjustments.
c. Belts/cutting blades/Hydro-Gear filters.
d. Engines - All engines used on Dixon ZTR mowers are warranted by the individual engine
manufacturer.
e. Any costs or expense of providing substitute equipment while repair work is being
performed on a warranted mower.
7. 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.
Blue/Customer Yellow/Dealer White/Dixon Ind.
WARRANTY VALIDATION: At the time of sale, selling dealer must review each portion of this
warranty document, complete the information section below, secure customer’s signature &
send copy to Dixon Industries, Inc.
DATE OF PURCHASE____________________MODEL_________________S/N______________
___________________________________ ____________________________________
Owner’s Name Dealership
___________________________________ ____________________________________
Address Address
___________________________________ ____________________________________
______________________________ _______________________________
Owner’s Signature Dealer’s Signature
DIXON INDUSTRIES, INC.
aBLOUNTcompany
AirportIndustrialPark
P.O. Box 1569
Coffeyville, Ks 67337- 0945
620-251-2000
Fax [phone]

13
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.
MOWERDECK: 42”Deck: 13 GA Stamped Steel Construction-42” CutWidth
50”Deck:11GAFabricatedConstruction/Reinforcement Ribs-50”
Cut Width
Cut height approximately 1” to 4” via 7 position lift handle.
BLADEDRIVE: Electric clutch.
TRANSMISSION: Each rear wheel is independently driven by a HydroGear IZT
hydrostatic drive.
ENGINE:
Model 4515B: 15.5 HP Briggs & Stratton Intek ELS (Extended Lift Series), 4-Cycle,
SingleCylinder,OverheadValve,Air-Cooled,Gasoline,VerticalShaft
with Cast Iron Cylinder Sleeve, Full pressure lube with spin-on filter
Chrome Valves, Plasma Piston Rings, Pteff Pistons, Platinum Spark
Plugs,AVS(Anti-vibration System) and extendedwarranty.
Model 4516K: 16HP Kohler Command460 cc, SingleCylinder, Overhead Valve,
AirCooled, Gasoline, Pressure Lubricated with oil filter, Vertical
Shaft,AluminumHead andBlock withCast-Iron CylinderLiner.
Model4518K: 18 HPKohler CommandTwin Cylinder,Overhead Valve,AirCooled,
Gasoline, Pressure Lubricated with oil filter, Vertical Shaft,
AluminumHeadand BlockwithCast-IronCylinderLiner.
STARTING Electric by key switch operation with safety interlock blade drive.
SYSTEM :
TIRES: Front 11 x 4.00 x 5 ribbed tread
Rear 18 x 8.50 x 8 Turf Trac R/S
RECOMMENDED Front 16-21PSI
TIREPRESSURE: Rear 8-14PSI
CAPACITIES: Fuel 2.7gallonstotal
Engine B&S- 1.5quartsoil Kohler - 2 quarts oil with filter
DIMENSIONS: Width 44” maximum track width
Height 42” to top edge of seat
Length 72” hitch tab to front bumper
Weight PowerUnit: 463lbs.
w/42” Deck: 547lbs.
w/50” Deck: 603lbs.
Additionalinformation providedin service instructionsunder the individualcomponent.
SPECIFICATIONSSUBJECTTOCHANGEWITHOUTNOTICE

14
SEAT ADJUSTMENT INSTRUCTIONS
Model ZTR 4515B, 4516K & 4518K
1. Raise and push seat assembly forward.
2. Loosen five nuts and slide seat forward or
backward to desired position.
3. Re-tightennuts. DO NOToperatemower
withoutseatadjustmentsproperlytightened.
4. Push seat assembly back to closed position.

15
CONTROLS
CONTROLLEVERS
Note: For access to the seat, move control levers to neutral position and
swing them outward.
TOGOFORWARD:
•Fromneutral position,gently push bothcontrol leversforward.
•To increase speed, move levers further forward.
TO GO BACKWARD:
•From neutral position, gently pull both control levers toward you.
TURNING:
•Turning is controlled by moving one control lever slightly forward or
rearward of the other.
•To turn left, move left lever rearward of the right lever.
•To turn right, move right lever rearward of the left lever.
•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.
LEFT TURN OPPOSITE
Note: The pressure required to operate the mower is very light.

16
CONTROLS
PARKING BRAKE:
The parking brake is designed to hold the mower from
moving and is not intended for use in stopping the
mowerwhile it isinmotion. The enginewill stopif the
parking brake is engaged while the control levers are
inthedriveposition.
Engage parking brake
before starting engine.
TO SET PARKING BRAKE:
The hand operated parking brake is located on the
rightfender.
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
Allowsthemowertoturnonitsownaxis“ZEROTURNINGRADIUS”.
Eachlever controlsoneside ofthe mower.
NOTE: The pressure required to operate the mower is very light.
CAUTION

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 :
•Protectionoftheelectricalsystemisby(1)
15ampcircuitbreaker.
•Ifcircuitbreaker trips, pushbutton to
reset.
•Ifthisconditionrepeats,consultdealerfor
inspection and repair.
THROTTLECONTROLLEVER:
•Located on control panel to operator’s right.
•Throttle control for engine speed.
•Choke for engine starting (omit for 4518K).
•Throttlecontrol shouldbe setto
MAXIMUM or wide open setting to insure
adequate cooling of the engine and to
maintain mower deck blade speed while
mowing.
CHOKECONTROL (4518K only):
•Located on control panel to operator’s right.
•Choke for engine starting.
MOWER DECK CUT HEIGHT LIFT LEVER :
•Located to the left of the operator.
•Controlsthe cutting height.
•Sevenpositions of adjustment.
•Move lever in and forward to lower.
•Move lever in and back to raise.
NOTE: Always use highfor transport.
4518K
4515B & 4516K

18
OPERATION INSTRUCTIONS
The safe and successful operation of the 4500 Series
willdependuponthe operator havingthecorrect
knowledge of all controls used on the mower and making
goodjudgements about theterrainto bemowed.
NEVER allow anyone to operate the mower without
complete knowledge of all controls and their functions.
Duringinitialoperation,“learningtodrive”,setthrottleat
slow speed.
Soundjudgementbythe operator will preventaccidents.
BEFORE OPERATING MOWER:
1. Readenginemanufacturer’soperatingand
maintenanceinstructions.
2. Read and observe all safety instructions on your
mowerand in themanual.
3. Check engine oil.
4. Check fuel cap to be sure it 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).

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. Release parking
brake.
To engage the transmission, pull by-pass keeper, toward
rear of machine so hydro release lever returns to its
normal position.
NOTE: Before pushing or towing tractor, transmission
must be unlocked and parking brake released.
The tractor should never be pulled at more than
2 miles per hour or for any appreciable distance.

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 in ON position
c) Swing control levers in
d) Turn ignition switch to START
Engine should not turn over or attempt to start.