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Dixon ZTR 5421 manual

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Table of contents for the manual

  • Page 1

    [...]

  • 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. The information in this operator&apo[...]

  • Page 3

    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 ..............[...]

  • Page 4

    SAFETY RIDING LAWNMOWERS, IF IMPROPERLY O PERATED, 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[...]

  • Page 5

    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 satisfactori[...]

  • Page 6

    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 dra wbar 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 cr[...]

  • Page 7

    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 p urchase or 400 hours of use, whichever occurs first. Mowers used for residential homeowner applications ([...]

  • Page 8

    SPECIFICATIONS CHASSIS: 11 GA - rectangular tube. B ODY: 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 us e of high density closed cell foam, padded[...]

  • Page 9

    SET UP AND SERVICE 1. Seat Assembly Instructions 2. Upper Control Lever Installation 3. Mower Deck Installation 4. Deck Leveling 5. Final Preparation Page 6[...]

  • Page 10

    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 sta ndard flat washers (3020) and (3) 5/16 - 18 x 1 hex head nylok b[...]

  • Page 11

    UPPER CONTROL LEVER INSTALLATION 1 Raise rear body cover to fully open position. 2. Install flat washer on right hand swive l 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. Pro[...]

  • Page 12

    MOWER DECK INST AL LATION 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 c otter pin and washer after engine to mower dr[...]

  • Page 13

    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. LEVEL[...]

  • Page 14

    MO WER 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 chassi s. 2. Fill each cell with electrolyte (acid) to ring at bottom of fill cap. 3. Allow battery to sit for (1 0) minutes, r[...]

  • Page 15

    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 t[...]

  • Page 16

    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 moveme nt of hand levers) must be carefully controlled for safety and best mowing results. Never operate at high speed in [...]

  • Page 17

    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 [...]

  • 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[...]

  • Page 19

    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 s[...]

  • 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 . 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 [...]

  • Page 21

    Page 18[...]

  • Page 22

    FORWARD LEVER STOP ADJUSTMENT Page 19[...]

  • Page 23

    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 GREA SE: Name brand wheel bearing or multi - purpose grease CAUTION: The use of compressed air pressure g[...]

  • 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 u sed on your[...]

  • Page 25

    TROUBLESHOOTING MOW ER 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. Ex amination of one or more of the above will generally produce a quality [...]

  • Page 26

    DRIVE SYSTEM: TROUBLESHOOTING Page 23 SITUATION CAUSES REMEDY Mower pulls to one side or the other Drive adjustment Adjust per operators manual Consult your dealer for repai r 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 operat[...]

  • Page 27

    TROUBLE SHOOTING 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 conne ctions on battery Battery water low Wrong battery installed in mower Tighten or replace a[...]

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  • Page 37

    ZTR 5421 PARTS LIST 1108 Front Tire 3093 5/1 6" - 1 8 UNC X 1 " HH Bolt GR5 1109 Inner Tube - Front Wheel 3100 7/1 6" HD Flat Washer 1384 Tank Mount Bracket (Short) 3106 1/4"X1" Spiral Pin 1385 Tank Mount Bracket (Long) 3130 1/2" Contact Belleville Spring 1512 Rear Tire 3160 5/16" Flat Washer 1668 Drive Pulley 316[...]

  • Page 38

    ZTR 5421 PARTS LIST 4584 Start Cable 5643 Input Gear - GB 4585 Battery Ground Cable 5644 Bearing - Gearbox 4587 W ire Cover 61 " 5645 Bearing Spacer - GB 4589 Covered Key 5648 CW Fan - Machined 4594 Wire Cover 14" 5649 CC W Fan - Machined 4598 Circuit Breaker 5650 Hydro 4645 Wire Cover 30" 5651 Hydro 4733 Seat Bottom 6065 Serpentine [...]

  • Page 39

    ZTR 5421 PARTS LIST 8576 Rear Rim 9624 Lift Cam Drilled RH 8688 Mower Blade Hi - Lift 9634 Lift Frame Weldment 8772 Belt Set (1859) 9646 Lift Plate 8852 Fuel Line 26.5 9655 Lift Shaft Weldment 8854 Fuel Li ne 6" 9031 Spacer 9049 Lift Bushing Bracket 9067 Control Rod 9082 Seat Frame Pivot Rod 9098 L - Rod9/16"X153/16" 9110 Tank Cover [...]

  • Page 40

    Page 36 NOTES[...]

  • Page 41

    NOTES Page 37[...]

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    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[...]