Dixon ZTR 5421 Operator's Manual
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Dixon ZTR 5421 Operator's Manual

Dixon ZTR 5421 Operator's Manual

Dixon lawn mower operator's manual
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  • Page 2 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.

  • Page 3: Table Of Contents

    INDEX 1. SAFETY ... Pages 1- 3 2. WARRANTY POLICY... Page 3. SPECIFICATIONS ... Page 4. SET UP AND SERVICE ... Pages 6 -1 1 5. OPERATION INSTRUCTIONS... Pages 12 - 3 6. CARE AND MAINTENANCE ... Pages14- 21 7. TROUBLESHOOTING ... Pages 22 - 24 8.

  • Page 4: Safety

    RIDING LAWNMOWERS, IF IMPROPERLY OPERATED, CAN CAUSE SERIOUS INJURY The following examples are the most common causes of injury to the 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.
  • Page 5 When the mower is not in use, turn the engine off and remove key. Never leave the engine running unattended. Your Dixon mower is equipped with a weight-sensitive switch that kills the engine when operator leaves the seat while blades are engaged.
  • Page 6 SAFETY REMINDERS: Never lift lawnmower by the body, lift only by the frame. Never carry passengers. Use care when pulling loads or using heavy equipment. Use ONLY approved drawbar hitch points. Limit loads to those you can safely control. Do not turn sharply. Use care when backing. Watch out for traffic when crossing or near roadways.

  • Page 7: Warranty Policy

    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.

  • Page 8: 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. Designed for operator comfort by use of high density closed cell foam, padded SEAT: back and arm rests.

  • Page 9: Set Up And Service

    SET UP AND SERVICE Page 6 Seat Assembly Instructions Upper Control Lever Installation Mower Deck Installation Deck Leveling Final Preparation...
  • Page 10 SEAT ASSEMBLY INSTRUCTIONS 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. 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).

  • Page 11: Upper Control Lever Installation

    UPPER CONTROL LEVER INSTALLATION Raise rear body cover to fully open position. Install flat washer on right hand swivel plate weldment. Next install right hand control lever, then second flat washer. Push control lever into the neutral slot and install (2) cup washers, (1) flat washer and jam nut.

  • Page 12: Mower Deck Installation

    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.

  • Page 13: Mower Deck Leveling Procedure

    MOWER DECK LEVELING PROCEDURE LEVELING PRINCIPALS: 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.

  • Page 14: Final Preparation

    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: Remove battery from chassis. Fill each cell with electrolyte (acid) to ring at bottom of fill cap. Allow battery to sit for (1 0) minutes, re-check acid level and top off any cells that are low.

  • Page 15: Operation Instructions

    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.
  • Page 16 OPERATION INSTRUCTIONS: 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.
  • Page 17 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.
  • Page 18 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.
  • Page 19 CARE AND MAINTENANCE - MODEL 5421 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.
  • Page 20 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 3/4".
  • Page 21 Page 18...
  • Page 22 FORWARD LEVER STOP ADJUSTMENT Page 19...
  • Page 23 CARE AND MAINTENANCE - MODEL 5421 CHASSIS AND MOWER DECK: Number of grease zerks used: (7) LOCATIONS: SERVICE INTERVALS: RECOMMENDED GREASE: CAUTION: The use of compressed air pressure greasing methods is ENGINE OIL CHANGES: OIL RECOMMENDATIONS: SERVICE INTERVALS: PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS. Page 20 LUBRICATION (1) each front wheel caster, front wheel, and deck hub for...
  • Page 24 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.

  • Page 25: Troubleshooting

    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. Your Dixon ZTR Dealer is also available to provide assistance to you. SITUATION CAUSES...
  • Page 26 DRIVE SYSTEM: SITUATION CAUSES Mower pulls to one Drive adjustment side or the other Loss of drive power T-Box belts slipping on one side or the other Loss of power on both Belt from engine to wheels after being T-Box is slipping operated for a length of time Operation of mower...
  • Page 27 ELECTRICAL SYSTEM: SITUATION CAUSES Starter will not Circuit breaker engaged turn engine over Dead battery Starter will not turn engine over Battery discharge Poor connections on battery Battery water low Wrong battery installed in mower Battery discharge Engine electrical system not functioning correctly Battery discharge Engine being operated...
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  • Page 37 5/16"-18 UNC X 3/4" HH Bolt GR5 3088 1/4"-20X1"HH BoltGRS 3091 1/2"-20 UNF Hex Lug Nut Page 32 ZTR 5421 PARTS LIST 3093 5/1 6"-1 8 UNC X 1 " HH Bolt GR5 3100 7/1 6" HD Flat Washer 3106 1/4"X1"...
  • Page 38 ZTR 5421 PARTS LIST 4584 Start Cable 4585 Battery Ground Cable 4587 Wire Cover 61 " 4589 Covered Key 4594 Wire Cover 14" 4598 Circuit Breaker 4645 Wire Cover 30" 4733 Seat Bottom 4761 Seat Switch Assembly 4783 Upper Wire Loom...
  • Page 39 ZTR 5421 PARTS LIST 8576 Rear Rim 8688 Mower Blade Hi-Lift 8772 Belt Set (1859) 8852 Fuel Line 26.5 8854 Fuel Line 6" 9031 Spacer 9049 Lift Bushing Bracket 9067 Control Rod 9082 Seat Frame Pivot Rod 9098 L-Rod9/16"X153/16" 9110...
  • Page 40 Page 36 NOTES...
  • Page 41 NOTES Page 37...
  • Page 42 Page 38 NOTES...
  • Page 43 DIXON INDUSTRIES, INC A BLOUNT COMPANY AIRPORT INDUSTRIAL PARK PO BOX 1569 COFFEYVILLE KS 67337 O945 316 251 2OOO FAX 316 251 4117...

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