Dixon ZTR 5421 User manual

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 dealer for warranty service, parts and repairs.

DIXON INDUSTRIES, INC

A BLOUNT COMPANY

AIRPORT INDUSTRIAL PARK

PO BOX 1569

COFFEYVILLE KS 67337 O945

316 251 2OOO

FAX 316 251 4117

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. TROUBLESHOOTING ......................................... Pages 22 -24

8. PARTS ILLUSTRATIONS..................................... Pages 25 -31

9. PARTS LIST ......................................................... Pages 32 -35

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. RUN-OVER: This situation occurs when a bystander is run-

over or backed over by the

mower. The

most frequently cited examples are with small children who

wander into, or are allowed to play in an area where the mower is being

operated. Never run the mower blades when there are people nearby,

especially children. Young children should be indoors and

watched by

an adult. Always look behind you before backing up.

3. TIP-OVER:

This occurs when the mower tips over, usually sideways or to the rear.

This situation is due to operation of the mower on steep inclines or near

a drop-off. Mow across the slope

to slightly uphill. Mow slopes when

the grass is dry and watch for bumps, holes and other obstacles. Test

the slope with the blades off. A good rule of thumb is "Don't mow on a

slope you can't back up". Stay clear of drop-

offs, especially if they are

on the down side of a slope.

4. THROWN OBJECTS:

The fast spinning mower deck blade can strike stones or other objects

which can be hurled into the path of a

bystander. To prevent this from

happening, never remove the safety discharge chute from the mower

deck, or operate the mower when other people are around.

5. FIRES: Most accidents of this type occur during re-

fueling of the rnower or

placing the mower in a storage situation. The exhaust system and

related engine components operate at very high temperatures

which

can ignite any fuel spilled on or near them. Always allow the mower to

cool before re-fueling or placing in storage.

6. OPERATION BY

CHILDREN:

This mower is not a toy or a recreational vehicle. Never allow children

to operate the mower in any manner or to ride as a passenger.

NOTE:

The six examples are the most frequently cited injury causing situations. Please review

all the safety precautions outlined on the following pages prior to operation of the

mower. Our aim is to enhance the safe and satisfactory use of this product.

Page 1

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 deflector is in place.

6. When mowing hills or slopes, use extreme caution. Reduce speed, do not make sudden starts,

stops or turns.

7. Always disengage blades before taking the mower across walks or objects that project above

the surface.

8. Stay alert for holes, rocks and roots in the terrain, and other hazards. Keep away from

drop-offs.

9. 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.

Note: This important safety feature must be tested prior to each mowing. This may be done by starting

engine, engaging blades and then rising slightly from seat. If engine does not stop, see your

dealer for necessary repair.

10. Before adjusting or servicing your mower, turn off the engine and let it cool. Be sure all moving

parts are stopped. Never run the 5421 with the body open.

11. Never run the engine indoors; the fumes are dangerous.

12. Before backing your Dixon Mower; stop, turn around and look.

13. Handle gasoline with care -it is highly flammable.

A. Use approved gasoline container.

B. Never remove the fuel cap of, or add gasoline to, a running or hot engine, or

an engine that has not been allowed to cool after running. Never fill the tank

indoors and always clean up spilled gasoline.

C. Never store the mower, with gasoline in the tank, inside the building where

fumes may reach an open flame or spark. Allow the engine to cool before

storing in any enclosure.

Page 2

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 place and working.

19. Keep all nuts, bolts and screws tight to be sure the mower is in safe working condition.

20. To reduce fire hazard, keep the engine free of grass, leaves or excessive grease.

21. The mower should be stopped and inspected for damage after striking a foreign object or if it

starts vibrating, and any damage should be repaired before restarting and operating the mower.

22. When mowing, proceed as follows:

A. Mow only in daylight or in good artificial light.

Shut the engine off when removing the grass catcher or unclogging chute.

C. Check the blade mounting bolts for proper tightness at frequent intervals.

D. Never operate the machine when using medication or under the influence of alc

ohol

or drugs.

Page 3

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 ZTR MOWERS

ARE WARRANTED AGAINST DEFECTS IN MATERIALS AND WORKMANSHIP AND PROVIDES FOR REPLACEMENT

OR REPAIR OF PARTS INCLUDING LABOR COSTS. THIS WARRANTY IS SUBJECT TO THE FOLLOWING

CONDITIONS AND LIMITATIONS:

1. Warranty applies only to original retail purchaser of new and unused mowers and accessories.

2. All Dixon warranty must be accomplished by authorized Dixon dealers and in accordance with Dixon warranty policy and

allowances. All warranty claims must be approved by Dixon Industries, Inc.

3. Battery warranty: Limited to 90 days from date of purchase.

4. Accessories Warranty (Grass Catchers, Snow Blades, Tine Rakes, Covers, etc.): Limited to 90 days from date of purchase.

5. Warranty does not apply to damage in transit or incidents of misuse, negligence, accidents, or alteration. The use of parts

or components other than those supplied by Dixon Industries, Inc. VOIDS ALL WARRANTY.

6. The following items are not covered by this warranty policy:

(a) Pick up and delivery charges for transportation of mower to and from an Authorized Dixon Dealer's place of business.

(b) Routine maintenance or adjustments.

(d) Engines -- All engines used on Dixon ZTR mowers are warranted by each individual engine manufacturer.

(e) Any costs or expense of providing substitute equipment while repair work is being performed on a warranted mower.

There is no other express warranty. Implied warranties, including those of merchantability and fitness for a particular

purpose, are limited to the same duration of the express warranty, and to the extent permitted by law any and all implied

warranties are excluded. Liabilities for consequential damages under any and all warranties are excluded.

Page 4

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 us

e 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 approximately

1 " to 4" via 7 position lift handle.

BLADE DRIVE: Electric clutch.

DRIVE SYSTEM: Each rear wheel is independently driven by a Hydro Gear BDU-

10L Series 70

hydrostatic transmission. The hydrostatic transmissions, in turn, power a fully

enclosed Hydro Gear gearbox. The gears in the Hydro Gear gearbox are

permanentl

y lubricated using a special grease which completely eliminates the

need for any type of maintenance.

The Hydro Gear BDU-

1 OL Series 70 hydrostatic transmissions are serviced with

any high quality 10W-30 motor oil. The oil is filtered by a 10 micron oil

filter.

Recommended service interval for filter is after the first 250 hours of operation,

then after every 400 hours of operation. If the system becomes contaminated by

dirt or other foreign debris, both oil and filter must be replaced immediately.

ENGINE: 16 HP Kohler Magnum, Vertical Crankshaft, 4-

Cycle, Air Cooled, Gasoline, Twin

Cylinder Opposed, Aluminum Crankcase, Removable Cast Iron Cylinder Barrels,

Electronic Ignition, Full Pressure Lubrication.

STARTING SYSTEM: Electric by key switch operation

with safety interlocks on parking brake and blade

drive clutch.

TIRES: Front 1 1 X 4.10 X 4 smooth profile.

Rear 1 8 X 9.5 X 8 turf savers.

CAPACITIES: Fuel -4.8 gallons total (dual tanks). Hydrostat oil tank -

3 quart with inline 10

micron filter. Hydrostat oil recommendation -name brand SAE 10W-

30 motor

oil.

DIMENSIONS: Width 51"

Height 45"

Length 72"

Weight 615lbs.

NOTE:

Additional information provided in service instructions under the individual

component.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.

Page 5

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

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.

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 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 utility box to seat back using (4) 5/1 6 standard flat

washers

(3020) and (4) 5/1 6-18x1 hex head nylok bolts (3224). Tighten all seat hardware at this time.

5. Place seat assembly on body, and connect seat safety switch.

6. Place (1) seat spacer (1849) on each stud protruding through seat bottom, and insert

studs

through slots in body. Firmly hold seat assembly against body with one hand while body is raised

to fully open position. Continue to hold seat against body to prevent damage to seat safety

switch wiring.

7. Install (1) 5/16 standard flat washer (30

20), (1) seat knob (3874), and (1) nylok nut (3205) on

each of the front studs extending through body and seat frame, and tighten these nuts.

Install (1) 5/16 standard flat washer (3020) and (1) nylok nut (3205) on each of the rear studs.

Do not fully

tighten these nuts, thus allowing for easy slide action of seat, as provided by knobs

on front studs.

Page 7

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