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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. See your dea
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INDEX 1. SAFETY ............................................................... Pages 1- 3 2. WARRANTY POLICY........................................... Page 4 3. SPECIFICATIONS ............................................... Page 5 4. SET UP AND SERVICE ....................................... Pages 6 -11 5. OPERATION INSTRUCTIONS............................. Pages 12 - 3 6. CARE AND MAINTENANCE ................................ Pages14- 21 7. TROUBLESH
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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. This situation occurs when a bys
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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. Do not operate mower unless deflec
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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. Limit loads to those you can safely control. C. 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 p
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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. DIXON
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SPECIFICATIONS CHASSIS: 11 GA - rectangular tube. Two piece - made of rotational molded polyethylene. Front body contains access BODY: 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. MOWER DECK: 13 GA stamped steel construction, 3 blades, 42" cut width, cut height app
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SET UP AND SERVICE Seat Assembly Instructions 1. 2. Upper Control Lever Installation 3. Mower Deck Installation 4. Deck Leveling 5. Final Preparation Page 6
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SEAT ASSEMBLY INSTRUCTIONS Assemble one arm rest bracket to arm rest cushion using (2) 5/1 6 standard flat washers (3020) 1. 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. Assemble arm rest brackets and utili
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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. Levers should no
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MOWER DECK INSTALLATION NOTE: Brake link (P/N 5283) normally used for installation of engine to mower deck drive belt, 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. 1. Loosen and remove front body mounting bolts (P/N 3368) and washers (P/N 3066). Disconnect headlight wiring plu
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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. Inf
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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. Trickle charge battery using a charger
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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. All controls are described from operators position: PARKING BRAKE: The parking brake used on the Model 5421
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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).
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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 reco
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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. In the
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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 fr
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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. The idler pulley travel required to engage the belt drive should be held to approximately 1. 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. Turn the rod as required to achieve desired pulley travel of approximately 1 3/4" when t
