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 Model 5421 Mowers. Your Dixon dealer will gladly provide a check-out ride, and answer any questions.
INDEX 1. 2. 3. 4. 5. 6. 7. 8. 9. SAFETY ............................................................... Pages 1- 3 WARRANTY POLICY........................................... Page 4 SPECIFICATIONS ............................................... Page 5 SET UP AND SERVICE ....................................... Pages 6 -1 1 OPERATION INSTRUCTIONS............................. Pages 12 - 3 CARE AND MAINTENANCE ................................ Pages14- 21 TROUBLESHOOTING ........................................
SAFETY RIDING LAWNMOWERS, IF IMPROPERLY OPERATED, CAN CAUSE SERIOUS INJURY The following examples are the most common causes of injury to the operator or bystander... 1. BLADE CONTACT: The operator or bystander inserts a hand or foot into the discharge chute or under the mower deck and into the path of the cutting blade. Never run the mower blades when there are people nearby. Always turn the engine off when cleaning or working around the mower deck. 2.
SAFETY SAFETY REMINDERS: READ CAREFULLY BEFORE OPERATION 1. Wear appropriate, safe clothing when mowing - close fitting jeans or slacks and heavy leather or safety shoes with rough soles. Never operate this mower with bare feet or open sandals. 2. Do not operate on wet or slippery grass. 3. Always mow at the slowest speed that will cut satisfactorily. 4. Keep hands and feet away from the blade at all times. 5. Keep persons clear of the discharge chute.
SAFETY REMINDERS: (Continued) 14. Never lift lawnmower by the body, lift only by the frame. 15. Never carry passengers. 16. Use care when pulling loads or using heavy equipment. A. Use ONLY approved drawbar hitch points. B. C. Limit loads to those you can safely control. Do not turn sharply. Use care when backing. 17. Watch out for traffic when crossing or near roadways. 18. Keep the mower in good operating condition, and keep safety devices in place and working. 19.
DIXON LIMITED WARRANTY POLICY -- HYDRO-GEAR MODELS This warranty policy applies to all Hydro-Gear mowers or any 50" model, purchased on or after March 1,1990. WARRANTY: Dixon Warranty term is for a period of one (1) year from date of purchase or 400 hours of use, whichever occurs first. Mowers used for residential homeowner applications (used only at owner's primary place of residence) are warranted for two (2) years from date of purchase or 400 hours of use, whichever occurs first.
SPECIFICATIONS CHASSIS: 11 GA - rectangular tube. BODY: Two piece - made of rotational molded polyethylene. Front body contains access panels for battery service and engine to mower deck belt removal. Rear body tilts up to allow service on the entire drive system. SEAT: Designed for operator comfort by use of high density closed cell foam, padded back and arm rests. Seat is adjustable fore and aft.
SET UP AND SERVICE Page 6 1. Seat Assembly Instructions 2. Upper Control Lever Installation 3. Mower Deck Installation 4. Deck Leveling 5.
SEAT ASSEMBLY INSTRUCTIONS 1. Assemble one arm rest bracket to arm rest cushion using (2) 5/1 6 standard flat washers (3020) and (2) 5/16-18 x 1 hex head nylok bolts (3224). Do not tighten hardware at this time. 2. Assemble arm rest bracket/cushion to seat bottom using (3) 5/16 standard flat washers (3020) and (3) 5/16-18 x 1 hex head nylok bolts (3224). Do not tighten hardware at this time. 3. Repeat steps 1 and 2 for other arm rest bracket. 4.
UPPER CONTROL LEVER INSTALLATION 1 Raise rear body cover to fully open position. 2. Install flat washer on right hand swivel plate weldment. Next install right hand control lever, then second flat washer. 3. Push control lever into the neutral slot and install (2) cup washers, (1) flat washer and jam nut. (See illustration) 4. Tighten jam nut. Proper tightness or tension on jam nut is achieved when swing out movement of upper control levers requires some pressure.
MOWER DECK INSTALLATION NOTE: Brake link (P/N 5283) normally used for installation of engine to mower deck drive belt, 1. has been placed in position during assembly of the lift frame at the factory. For shipment purposes, the brake link has been secured with a cotter pin and washer. REMOVE AND DISCARD cotter pin and washer after engine to mower drive belt has been installed. Loosen and remove front body mounting bolts (P/N 3368) and washers (P/N 3066).
MOWER DECK LEVELING PROCEDURE LEVELING PRINCIPALS: A. There are a total of (4) threaded adjusters which will control the attitude or pitch of the mower deck. The adjusters have lock nuts on the bottom which can be turned up or down to raise or lower the front and rear of the mower deck. Deck should be level or pitched slightly higher in rear. LEVELING THE DECK: A. Place the mower on a smooth level surface, check tire pressures to insure the mower has a correct stance.
FINAL PREPARATION MOWER DECK DEFLECTOR: Remove hair pin cotter (P/N 3072) from deflector pin (P/N 6297), remove pin. Position deflector (P/N 8799) on mower deck. Reinstall deflector pin and hair pin cotter. BATTERY: 1. Remove battery from chassis. 2. Fill each cell with electrolyte (acid) to ring at bottom of fill cap. 3. Allow battery to sit for (1 0) minutes, re-check acid level and top off any cells that are low. 4.
OPERATION INSTRUCTIONS The safe and successful operation of the Model 5421 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. Sound judgement by the owner will prevent accidents.
OPERATION INSTRUCTIONS: (Continued) BRAKING: To brake mower, move both levers in direction opposite of travel, release levers to neutral, set parking brake. Park only on level surfaces. GROUND SPEED: Ground speed (controlled by movement of hand levers) must be carefully controlled for safety and best mowing results. Never operate at high speed in unfamiliar areas or on slopes. CHOKE CONTROL LEVER: Used to start a cold engine. (Engine has not been operated for a length of time).
CARE AND MAINTENANCE - MODEL 5421 This portion of the Model 5421 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. NOTE: Due to the precision nature of the hydrostatic transmissions used on the Model 5421, internal service repairs cannot be recommended.
PROCEDURE FOR ELECTRIC CLUTCH ADJUSTMENT Dixon has used two types of electric clutches. One type is the Borg Warner and the second one is the Ogura. Even though these clutches come from different manufacturers, the test procedures are the same for both. Few people realize that clutches have maintenance procedures to extend the life of the clutch as they wear over time. Below is the information to make these maintenance adjustments and also a procedure to check for a faulty coil.
CARE AND MAINTENANCE - MODEL 5421 MOWER DECK SERVICE CUTTER BLADE REMOVAL - BELT TENSION: "CAUTION" The removal of the cutter blades for either sharpening or replacement is best accomplished by removing the deck assembly from the mower. DO A/OTattempt to raise or lift the front of the mower unless proper safety equipment is available to support the mower. If you do not have the necessary equipment, entrust this task to your dealer. DECK REMOVAL: 1 . Remove front belt access cover from body.
CARE AND MAINTENANCE - MODEL 5421 DRIVE SYSTEM ADJUSTMENTS: Adjustment of the drive system is limited to the actual function of the hydrostatic transmissions as outlined below. 1. The idler pulley travel required to engage the belt drive should be held to approximately 1 3/4". To adjust this distance, loosen the nuts on both ends of the rod extending between the idler plate and the brake shaft.
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FORWARD LEVER STOP ADJUSTMENT Page 19
CARE AND MAINTENANCE - MODEL 5421 LUBRICATION CHASSIS AND MOWER DECK: Number of grease zerks used: (7) LOCATIONS: (1) each front wheel caster, front wheel, and deck hub for front wheels SERVICE INTERVALS: Every 50 hours of operation RECOMMENDED GREASE: Name brand wheel bearing or multi-purpose grease CAUTION: The use of compressed air pressure greasing methods is not recommended as damage to seals and bearings could occur.
CARE AND MAINTENANCE - MODEL 5421 CLEANING THE MOWER: A clean machine is a source of pride to the owner. However, cleaning by use of high pressure commercial washes is not recommended. The high water pressure, combined with solvents or alkaline detergents, can lead to corrosion of electrical components or damage to the sealed bearings used on your mower. A better approach is the use of the mild household soaps and low water pressure. A stiff brush can be used to loosen excess grass and dirt build up.
TROUBLESHOOTING MOWER CUT QUALITY: There are many variables that can effect the cut quality of any multi-blade 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.
Page 23 TROUBLESHOOTING DRIVE SYSTEM: SITUATION CAUSES REMEDY Mower pulls to one side or the other Drive adjustment Adjust per operators manual Consult your dealer for repair Loss of drive power on one side or the other T-Box belts slipping Adjust per operators manual Consult your dealer for repair Loss of power on both wheels after being operated for a length of time Belt from engine to T-Box is slipping Adjust per operators manual Consult your dealer for repair Poor driving performance Ope
TROUBLESHOOTING ELECTRICAL SYSTEM: SITUATION CAUSES REMEDY Starter will not turn engine over Circuit breaker engaged 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 Battery water low Wrong battery installed in mower Tighten or replace as required Battery discharge Engine electrical system not functioning correctly Have electrical system checked by your dealer Battery discharge Eng
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ZTR 5421 PARTS LIST 1108 1109 1384 1385 1512 1668 1685 1687 1701 1751 1763 1826 1849 1850 1851 1860 1863 1938 2128 2475 2533 2648 2995 3002 3005 3006 3007 3008 3009 3012 3014 3019 3020 3023 3033 3052 3057 3061 3066 3068 3072 3074 3087 3088 3091 Front Tire Inner Tube - Front Wheel Tank Mount Bracket (Short) Tank Mount Bracket (Long) Rear Tire Drive Pulley L-Rod Idler Pulley Wheel/Deck Hub Bearing Transaxle Idler Pulley Tie Down w/lnsulator Caster Bushing Seat Spacer Drive Pulley 4" A-Pulley V-Belt Caster Tu
ZTR 5421 PARTS LIST 4584 4585 4587 4589 4594 4598 4645 4733 4761 4783 4784 4979 5070 5085 5170 5189 5242 5249 5257 5283 5522 5525 5530 5531 5537 5540 5554 5558 5559 5560 5561 5562 5563 5564 5565 5585 5595 5602 5624 5625 5632 5633 5635 5636 5641 Start Cable Battery Ground Cable Wire Cover 61 " Covered Key Wire Cover 14" Circuit Breaker Wire Cover 30" Seat Bottom Seat Switch Assembly Upper Wire Loom Lower Wiring Loom Hinge Key 3/16" SqX 7/8" Brake Band Spring Bushing Plug w/Hole 5/8" Bearing w/Snap Brake Dru
ZTR 5421 PARTS LIST 8576 8688 8772 8852 8854 9031 9049 9067 9082 9098 9110 9142 9156 9157 9158 9159 9164 9165 9171 9172 9174 9191 9196 9212 9268 9280 9312 9325 9329 9330 9332 9334 9335 9336 9339 9342 9344 9346 9347 9350 9372 9374 9377 9618 9623 Rear Rim Mower Blade Hi-Lift Belt Set (1859) Fuel Line 26.
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DIXON INDUSTRIES, INC A BLOUNT COMPANY AIRPORT INDUSTRIAL PARK PO BOX 1569 COFFEYVILLE KS 67337 O945 316 251 2OOO FAX 316 251 4117
