999 Operator's Manual 4500 SERIES
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 this operator's manual applies to all Dixon® ZTR® 4500 Series Model Mowers. Your Dixon dealer will gladly answer any questions.
INDEX SAFETY ................................................................. Pages WARRANTY POLICY.............................................. Page SPECIFICATIONS .................................................. Page SEAT ADJUSTMENT ............................................. Page CONTROLS ........................................................... Pages OPERATION INSTRUCTIONS ................................ Pages CARE AND MAINTENANCE .................................. Pages STANDARD PARTS LIST ..
SAFETY RIDING LAWNMOWERS, IF IMPROPERLY OPERATED, CAN CAUSE SERIOUS INJURY OR DEATH The most common causes of injury to the operator or bystander... BLADE CONTACT TIP-OVER BACK-OVER ...read and understand this manual to prevent injuries.
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 which, if not avoided, could result in death or serious injury.
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.
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.
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.
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.
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 Protection Plus Warranty term is for a period of two (2 ) years from date of purchase. DIXON ZTRMOWERSAREWARRANTEDAGAINSTDEFECTSINMATERIALSANDWORKMANSHIPANDPROVIDESFOR REPLACEMENT ORREPAIROFPARTSINCLUDING LABORCOSTS. THISWARRANTYIS SUBJECT TOTHE FOLLOWING CONDITIONSANDLIMITATIONS: 1.
SPECIFICATIONS 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.
SEAT 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 assembly and upper body rearward to closed position.
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
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).
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.
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. 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 and repair. MOWER DECK CUT HEIGHT LIFT LEVER: Located to the left of operator. Controls the cutting height. Seven positions of adjustment.
OPERATION 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, "learning to drive", set throttle at slow speed. Sound judgement by the operator will prevent accidents.
OPERATION INSTRUCTIONS TESTING OF SAFETY INTERLOCK SYSTEMS: PARKING BRAKE SWITCH TEST: a) b) c) d) Swing out control levers Disengage blade drive switch Put Parking brake in OFF position Turn ignition switch to START Engine should not turn over or attempt to start. CONTROL LEVER SWITCH TEST: a) b) c) d) Disengage blade drive switch Put parking brake in ON position Swing control levers in Turn ignition switch to START Engine should not turn over or attempt to start.
OPERATION INSTRUCTIONS CAUTION Engage parking brake before starting engine. 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.
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. In order to achieve the best results, please read and follow the mulching tips listed below: 1. Set the engine speed control to the wide open or full setting. 2.
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. 1. Some applications may require installation of an "Optional" weight box on the front of the mower to offset cut grass weight. 2. Set engine speed control to the wide open or full setting. 3. Do Not Attempt To Cut Grass When It Is Wet.
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. 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.
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. MAINTENANCE SCHEDULE: To insure a long and trouble free service life of all components, a regular and thorough maintenance schedule should be followed.
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. CAUTION Wear heavy, thick gloves when holding onto mower blade, avoid the sharp edge of the blade. Note: Be sure blade is center on pilot before tightening nut to 60 ft. lbs. torque.
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" 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.
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 now uneven at top speed, loosen control lever mounting nut. Rotate lever to be even with other side and tighten nut.
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.
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.
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.
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.
CARE AND MAINTENANCE CAUTION HOT oil may cause burns. Allow engine to cool before draining oil. 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.
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.
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: Keep all connections clean and tight. CLEANING THE MOWER: Wash mower periodically. Clean above and below deck. NOTE: Allow mower to cool before washing. If bearings are hot, they will draw moisture inside as they dry and cause corrosion.
STANDARD SERVICE PARTS LIST 36" DECK: BLADES: Standard: Hi-Lift: BELTS: Engine To Mower Deck: P/N 1300 Engine To Transmission: P/N 5768 BLADES: Standard Hi-Lift: Lo-Lift: BELTS: Engine To Mower Deck: P/N 5861 Serpentine Belt: P/N 6109 Engine To Transmission: P/N 5768 BLADES: Standard Hi-Lift: 42" DECK: P/N 1324 P/N 1351 Right Side P/N 1352 Left Side P/N 8688 P/N 6236 50" DECK" Lo-Lift: BELTS: P/N 9444 P/N 9443 Engine To Mower Deck: P/N 7174 Serpentine Belt: P/N 1300 Engine To Transmission: P/
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 variables 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.
TROUBLESHOOTING DRIVE SYSTEM: SITUATION CAUSES REMEDY Mower creeps in neutral position Neutral adjustment 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 .
TROUBLESHOOTING ELECTRICAL SYSTEM: SITUATION CAUSES REMEDY Starter will not turn engine over Circuit breaker disengaged Push button to reset Consult your dealer for repair Starter will not turn engine over Dead Battery Charge battery Battery discharge Poor connections on battery Tighten or replace as required Battery water low Wrong battery installed in mower Battery discharge Engine electrical system not functioning correctly Have electrical system checked by your dealer Battery discharge
OWNER INFORMATION DIXON INDUSTRIES, INC. A BLOUNT International Inc. Co.
Engine Exhaust from this product contains chemicals known to the WARNING: 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. PO BOX 1569 COFFEYVILLE KS 67337 0945 316 251 2000 4500 Series Part No.
