4500 SeriesZTR®Model Year 2004
10SERVICE:Use extra care in handling gasoline and other fuels.They are flammable and vapors are explosive.Use only an approved container.Never remove
11SERVICE (continued):Never run a mower inside a closed area. The exhaustfumes are toxic.Keep nuts and bolts tight, especially blade attachmentbolts,
12CHILDREN:Tragic accidents can occur if the operator is notalert to the presence of children.Children are attracted to lawn mowers and themowing act
13DIXON LIMITED WARRANTY POLICYRESIDENTIAL HYDRODIXON ZTR MOWERS ARE WARRANTED AGAINST DEFECTS IN MATERIALS ANDWORKMANSHIP AND PROVIDES FOR REPLACEMEN
14Model ZTR 4515, 4516 & 4518Chassis: Twin 12 gauge side frames and 7 gauge transmission and enginebase plate.Body: All body parts made of high de
15SEAT ADJUSTMENT INSTRUCTIONSModels ZTR 4515, 4516 & 45181. Grasp seat slide adjuster andmove it into adjustment position.2. Slide seat forward o
16CONTROL LEVERSNote: For access to the seat, move control levers to neutralposition and swing them outward.TO GO FORWARD•From neutral position, gentl
17PARKING BRAKE:The parking brake is designed to hold themower from moving and is not intended foruse in stopping the mower while it is inmotion. The
18BLADE 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 dow
19The safe and successful operation of the 4500 Serieswill depend upon the operator having the correctknowledge of all controls used on the mower andm
IMPORTANT - READ CAREFULLYThe Dixon® ZTR® mower is both easy andfun to operate. However, any power mowermust be operated properly to be safe. It isn
20TOWING TRAILERS AND OTHER ATTACHMENTS:Towing a trailer or other attachment that is too heavy coulddamage the drive or cause the mower to become unst
21PARKING BRAKE SWITCH TEST:a) Swing out control leversb) Disengage blade drive switchc) Put parking brake in OFF positiond) Turn ignition switch to S
22BLADE DRIVE SWITCH TEST:a) Put parking brake in ON position.b) Swing out control levers.c) Engage blade drive switch.d) Turn ignition switch to STAR
23STARTING INSTRUCTIONS (4515 & 4516):1. Parking brake must be on, control levers swung out, and bladedrive disengaged.2. Move throttle control to
24OPERATION INSTRUCTIONSSTARTING INSTRUCTIONS (4518):1. Parking brake must be on, control levers swung out, andblade drive disengaged.2. Engage choke
25SIDE DISCHARGE OF THE CLIPPINGS:In order to achieve optimum performance whenSide discharging the grass clippings, please readand follow the tips lis
26MOWING WITH A MULCHING ATTACHMENT:Mulching or recycling the grass clippings requires atotally different mowing approach than would benormal when sid
27MOWING WITH A MULCHING ATTACHMENT(continued):6.Keep the Underside Of The Mower Deck Clean.Remove all grass and dirt build-up from theunderside of th
28MOWING WITH A GRASS CATCHERATTACHMENT:In order to achieve optimum performance whenmowing with a grass catching attachment, pleaseread and follow the
29 CAUTION•Watch for low hanging branches or other obstacleswhich might hit the catcher top while turning orbacking the mower.•Use care when backing t
3INDEXPageSafety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12Warranty Policy. . . . . . . . . . . . . . . . . . . . . . . . . . .13
30GRASS HEIGHT & CUTTING SUGGESTIONS:Do not attempt to cut grass when it is wet.If the grass is tall, place the mower deck cut heightlever in the
31CAUTIONCAUTIONCAUTIONCAUTIONCAUTIONBefore performing any maintenance, turn off engine,allow to cool & remove key.Use extreme care when working
32ENGINE:For complete maintenance and operating information of the engine,please refer to the maintenance instructions furnished by theengine manufact
33CUTTER BLADE MAINTENANCE:CAUTION Stop engine and remove ignition keyfor safety. Wear heavy, thick gloveswhen holding onto cutter blade, avoidthe sh
34BELTS:Check belts every 50 hours. Replace any belts found tobe in poor condition.BELT TENSION:42” DeckMower Deck Serpentine Belt-P/N 6109Manual adj
35FORWARD TRAVEL SPEED ADJUSTMENT1. Drive machine until hydrostats have warmedup.2. Drive on a smooth, level surface with bothlevers in top speed posi
36NEUTRAL ADJUSTMENTDRIVE MACHINE UNTIL HYDROSTATS HAVE WARMED UP.WITH ENGINE RUNNING AND THE PARKING BRAKE OFF, SWINGOUT THE CONTROL LEVERS. IF MACHI
37NEUTRAL ADJUSTMENT (continued)4. Stop engine and remove rear of machine from jack orblocks.5. Drive machine with both levers in top speed position.
38CARE AND MAINTENANCEMOWER DECK LEVELING PROCEDURE:1. Place mower on a smooth, level surface andcheck tire pressures to insure correct stance.Tires s
39MOWER DECK LEVELING PROCEDURE(continued):NOTE: This will place the mower deck in a basemeasurement position. Additionaladjustment may be required t
4Blade ContactTip OverRun OverBack OverSAFETYRIDING LAWN MOWERS,IF IMPROPERLY OPERATEDCAN CAUSE SERIOUS INJURY OR DEATHThe most common causes of injur
40DECK REMOVAL:1. Place cut height lever in lowest cut position.2. Pull belt idler back to allow belt to be removed from idlerpulley and electric clut
41LUBRICATION:CHASSIS: (5) grease zerksLOCATIONS: (1) each front wheel caster(1) each mower deck hubSERVICE INTERVALS: Every 50 hours of operationor o
42CHANGING THE ENGINE OIL:1. The “Dapco” oil drain valve is located on the leftside of the engine crankcase (Model 4515 &4518) and on the right si
43CARE & MAINTENANCE HOT oil may cause burns. Allow engine to cool before draining oil.OIL FILL:1. Clean any spilled oil from engine and
44CARE & MAINTENANCEELECTRICAL SYSTEMS:Keep all connections clean and tight.CLEANING THE MOWER:Wash mower periodically. Clean above and belowdeck
45NOTESCARE & MAINTENANCE
46STANDARD SERVICE PARTS LIST42” Deck~Blades~Hi-Lift - P/N 8688 (Standard)Lo-Lift - P/N 6236~Belts~Engine to Mower Deck - P/N 5861Serpentine - P/N 610
47STANDARD SERVICE PARTS LISTBRIGGS & STRATTON AIR AND OIL FILTERSRefer to Briggs & Stratton Engine Operator’s Manualfor correct service inter
481. ENGINE WON’T TURN OVERMower blades engaged- - - - - - - - - - - - - - - - - - - disengage bladesParking brake not on- - - - - - - - - - - - - - -
49TROUBLESHOOTING6. ENGINE RUNS BUT MOWER WON’T MOVE FORWARDDrive belt broken or slipping- - - - - - - - - - - - - - - - replace drive beltTransmissio
5Safety Alert SymbolWhen you see this symbol, BE ALERTto the potential for injury.Follow recommended safety precautionsand safe operating practices.DA
NameAddress DATE OIL CHANGED DATE ENGINE TUNEDDIXON INDUSTRIES, INC.a BLOUNT International Inc. Co.P.O. Box 1569Coffeyville, Ks 67337-0
ZTR®MowersZTR®MowersZTR®MowersZTR®MowersZTR®MowersDixon® and ZTR® are registered trademarks ofDixon Industries, Inc.DIXON INDUSTRIES, INC.a
6Failure to observe the following safety instructionscould result in serious injury or death.GENERAL OPERATION:Read, understand, and follow all instru
7GENERAL OPERATION (continued):Stop engine before removing grass catcher or unclog-ging chute.Mow only in daylight or good artificial light.Do not ope
8SLOPE OPERATION:Slopes are a major factor related to loss-of-controland tip-over accidents,which can result in severe injury or death.All slopes requ
9SLOPE OPERATION (continued):DO (continued):Avoid starting or stopping on a slope. If tires losetraction, disengage the blades and proceed slowlydown
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