Dixon 5421 Lawn Mower User Manual
Contents
1. 12 5 Soze see i d DEN 0115 sl 28 4 pue syueL jand 2 EN 4 hy 9 56055 Ser SC 2 1955 21425 595 9 0955 7995 sess BIZE 29 Aiquessy 12 6 5628 LIM WOOT H 412 91043705 285 3313 15 OJ 91043705 1 15 1535 A Am Ay SIN HOLLING fie E 654 8347 1105415 8657 MOLNIS 31819313 30 E lt a gt 31 5000 Series Gearbox Assembly ZTR 5421 PARTS LIST 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 wilnsulator Caster Bushing Seat Spacer Drive Pulley 4 A Pulley V Belt Caster Tube Anchor Bracket Sleeve Control Rod Brake Rod Deck Hub Key Commercial Decal 5 16 18X21 2 HHBoltGR8 5 16 18UNCHexNut 5 16 18X1 1 4 HH Bolt GR5 1 4 20 UNC Hex Nut 1 4 ID2. Page 7 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 not fall to the side or be sloppy in movement 5 Repeat above procedure left side Page 8 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 plug from wiring harness Lift front body from chassis 2 Install rear hanger rods on lift frame Slide lift plate on hanger rods small holes in lift plate will face rear of mower and start nylok nuts on each hanger rod until approximately 1 2 inch of threads are exposed 3 Position mower deck under chassis 4 Raise front of mower deck and slide front support rod t
3. Install permanent battery caps and wash accumulated acid from battery before re installation on chassis 6 Observe proper battery polarity when re connecting leads on chassis Always connect positive lead first ENGINE SERVICE Final preparation of engine should be completed using engine service manual provided with mower INITIAL START AND HYDROSTAT TRANSMISSION CHECK 1 Final hydrostat checks have been performed at the factory however it is necessary to check that the pressure relief bypass on each hydrostatic transmission is completely released before attempting to drive mower 2 Each hydrostat has a bypass relief pin located at the rear of the hydrostatic unit A bypass keeper is provided to allow the mower to be rolled around without complete servicing of the unit To accomplish this the bypass keeper springs must be positioned to depress the bypass relief pins Remove bypass keeper springs prior to actual operation of the mower 11 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 br
4. X 3 4 OD Flat Washer 5 1 6 18 UNC X 1 3 4 HH Bolt GR5 3 8 16UNCHexNut 1 4 20 UNC X 3 4 HH Bolt GR5 5 16 Helical Lock Washer 5 16 Std Flat Washer 1 4 Helical Lock Washer 1 2 SAE Flat Washer 3 32 X 1 Cotter Pin 3 8 Std Flat Washer 5 16 18 UNC 1 3 4 Soc Set Screw 3 1 6 Std Flat Washer 1 8 X1 Cotter Pin 1 8 X 1 3 4 Hair Pin Cotter 5 16 24UNFHexJamNut 5 16 18 UNC X 3 4 HH Bolt GR5 1 4 20X1 HH BoltGRS 1 2 20 UNF Hex Lug Nut 3093 3100 3106 3130 3160 3161 3163 3178 3182 3187 3188 3193 3195 3203 3204 3205 3206 3208 3217 3220 3224 3225 3227 3231 3235 3237 3247 3249 3256 3257 3266 3267 3268 3269 3272 3273 3297 3298 3300 3310 3318 3319 3321 3322 3325 5 1 6 1 8 UNC X 1 HH Bolt GR5 7 1 6 HD Flat Washer 1 4 X1 Spiral Pin 1 2 Contact Belleville Spring 5 16 Flat Washer 5 1 6 24 UNF LH Thread 1 2 Int Tooth Lock Washer 3 8 16 X 2 1 2 HH Bolt GR5 Flip Lock Bushing 10 32 Hex Nut 10 Ext Tooth Lock Washer 43 X 1 38 X 25 Face Nut 1 2 27 3 8 ID Flat Washer Narrow 1 4 20HexNutw Nylok 5 16 18HexNutw Nylok 3 8 16HexNutw Nylok 10 24 Hex Nut w Nylok 1 4 SAE Flat Washer 7 16 20 x 2 3 4 HH Bolt GR5 5 16 18 X 1 HH Bolt w Nylok GR5 3 8 16X21 4 HHBolt 5 16 18X2 HHBoltGR5 9 1 6 Std Flat Washer 10 24 X 5 8 Phillips Pan Hd Screw Eye Bolt 5 1 6 X 6 00 6 20 X 1 2 Phillips Pan Hd Screw 5 8 Int Tooth Lock Washer Snap Ring 7 16 Int Too
5. and other hazards Keep away from drop offs 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 10 11 12 13 Page 2 engine engaging blades and then rising slightly from seat If engine does not stop see your dealer for necessary repair 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 Never run the engine indoors the fumes are dangerous Before backing your Dixon Mower stop turn around and look 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 SAFETY REMINDERS Continued 20 21 22 Never lift lawnmower by the body lift only by the frame Never carry passengers Use care when pulling loads o
6. are removed Slide deck from under chassis 3 Reverse procedure to re install deck assembly CUTTER BLADE REMOVAL 1 Carefully place deck assembly in a manner which will allow access to the blade bolts Hold blade from turning while bolt is removed from the center of each hub assembly Caution wear heavy thick gloves when holding onto cutter blade avoid the sharp edge of the blade 2 When reassembling blades to hub assemblies fully tighten blade bolts to minimum of 60 ft Ibs torque The use of air impact tools is recommended for installation to insure bolt tightness BELT TENSION 1 The engine to mower deck drive belt on the Model 5421 is automatically held in proper tension by springs which push the deck assembly forward and does not require any additional adjustment to be made Both the belt and the idler system should be periodically inspected due to the nature of the job they perform 2 Serpentine deck belt tension is maintained by a manual adjustment rod which is located on the top of the mower deck assembly Proper belt tension is critical to insure cut quality If adjustment is required tighten lock nut on adjustment rod until belt free play or movement between pulleys is approximately 1 4 of an inch Page 16 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
7. blades Unlevel mower deck Grass build up under mower deck Improper blades Uneven tire pressures REMEDY Reduce mowing speed Adjust per operators manual Increase engine RPM to maximum Sharpen or replace as required Adjust per operators manual Clean out underside of mower deck Replace with original equipment blades which are designed for the Model 5421 Check and adjust as required per operators manual Page 22 23 TROUBLESHOOTING DRIVE SYSTEM SITUATION CAUSES REMEDY Mower pulls to one Drive adjustment Adjust per operators manual side or the other Consult your dealer for repair Loss of drive power T Box belts slipping Adjust per operators manual on one side or the Consult your dealer for repair other Loss of power on both Belt from engine to Adjust per operators manual wheels after being T Box is slipping Consult your dealer for repair operated for a length of time Poor driving Operation of mower Review operators section performance of owners manual Oil leaks Loose or missing Tighten or replace as required hose clamps ELECTRICAL SYSTEM SITUATION Starter will not turn engine over Starter will not turn engine over Battery discharge Battery discharge Battery discharge Electric clutch will not engage mower deck blades TROUBLESHOOTING CAUSES Circuit breaker engaged Dead battery Poor connections on battery Battery water low Wrong battery installed in mower Engin
8. 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 case that the clutch has failed a part the entire clutch must be replaced since there are no parts available A AIR GAP ADJUSTMENT 1 Remove the clutch from the engine This is recommended because it is easier to verify the gap 2 Locate the three rivet joints which fasten the leaf springs to the armature figure 1 3 Rotate the pulley until these rivet joints are located midway along the edge of the triangular field adapter figure 1 4 Locate the three holes in the brakeplate one near each adjustment nut figure 2 Armature rivet joints 3 tonl 5 Insert a 012 inch feeler gauge into one of the three windows Be careful to position the feeler gauge between the rotor and armature faces figure 3 figure 1 6 Tighten the adjusting nut adjacent to the window with the feeler gauge inserted until the gauge fits snugly between the rotor and armature The gap should not be so tight that the feeler gauge cannot be reinserted after removal 7 Repeat Steps 5 and 6 at the other two windows 8 Re check the air gap at each window and make minor adjustments as necessary to achieve a consistent 012 inch air gap 9 Reinstall the clutch to the engine Be sure to torque the mounting bolt back to 50 ft Ibs B OHMS TEST 1 Disconnect clutch from
9. 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 Turn the rod as required to achieve desired pulley travel of approximately 1 3 4 when the brake handle is released Tighten nuts firmly against the ball joint rod ends See Figure 1 2 The twisted idler belt P N 1 860 should be aligned in the center of the pulley To adjust the alignment tighten or loosen the nut which holds on the pulley as required until belt is visually centered on the pulley Start engine and disengage brake to determine whether pulley alignment is maintained during operation Shut off engine and repeat procedure if necessary See Figure 2 3 The brake bands should fit tightly around brake drums with the brake handle on and release drums with handle in the off position Brake handle should be placed in both and on positions several times to determine whether brake bands are functioning correctly If band is too loose tighten the nut on the threaded end of eyebolt extending from brake band If band does not release drum loosen nut until achieving desired results Repeat procedure if necessary See Figure 3 4 Neutral Adjustment Swing upper control levers out into the neutral slots Raise upper body to the fully open position Start engine and disengage parking brake Caution should be used when releasing p
10. 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 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 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 3020 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 8 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 4400 ARM REST OFFSET 4733 SEAT BOTTOM SEAT BACK UTILITY 5 16 STD FLAT WASHER 6 16 18 HEX NUT W NY SEAT SPACER SEAT KNOB 5 16 18
11. DIXON OPERATORS 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 0945 316 251 2000 FAX 316 251 4117 E ek leie ie INDEX Pages 1 3 WARRANTY e e Le E 4 SPECIFICATIONS 5 SET UP AND SERVICE Pages 6 11 OPERATION Pages 12 3 AND MAINTENANCE 14 21 TROUBLESHOOTING EE Pages 22 24 PARTS Pages 25 31 PARTS E 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 1 BLADE CONTACT 2 RUN OVER 3 TIP OVER 4 THROWN OBJECTS 5 FIRES 6 OPERATION BY CHILDR
12. EN operator or bystander 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 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 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 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 Most accidents of this type occur during
13. YEBOLT BRAKE BANO Figure 3 18 CARE AND MAINTENANCE MODEL 5421 CHASSIS AND MOWER DECK LOCATIONS SERVICE INTERVALS RECOMMENDED GREASE CAUTION ENGINE OIL CHANGES OIL RECOMMENDATIONS SERVICE INTERVALS LUBRICATION Number of grease zerks used 7 1 each front wheel caster front wheel and deck hub for front wheels Every 50 hours of operation Name brand wheel bearing or multi purpose grease The use of compressed air pressure greasing methods is not recommended as damage to seals and bearings could occur Using a hand pressure grease gun lubricate each front wheel to allow even distribution of grease within the wheel rotate or spin each front wheel after 3 pumps of the grease gun Repeat process until the appearance of grease is noted completely around each caster axle Refer to separate owners manual furnished by the engine manufacturer PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS PROTECT YOUR ENVIRONMENT Page 20 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 soap
14. ake used on the Model 5421 is designed to hold the mower from moving and is not intended for use in stopping the mower while it is in motion An additional safety feature of the parking brake is that the engine cannot be started unless the brake is applied HYDROSTATIC DRIVE SYSTEM Allows the mower to turn on its own axis zero radius Each lever controls one side of the mower The pressure required to operate the mower is very light and a minimum of 172 hour should be spent simply driving the mower in a non mowing application to gain the confidence necessary to mow like a pro LEVER MOVEMENTS No shifting or clutching required TO GO FORWARD Release parking brake From neutral position gently push both drive levers forward to increase speed move levers farther forward TO GO BACKWARD From neutral position gently pull both drive levers toward you TURNING Turning is controlled by moving one drive lever slightly forward or rearward of the other To turn left move left lever rearward of the right lever To turn square comers move lever of desired direction to neutral To turn on mower s own axis zero radius reduce speed and move one lever to reverse position and the other to forward position Page 12 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 c
15. arking brake as mower may tend to creep or move prior to adjustment If adjustment is required loosen lock nuts at each end of the control rods and back off the tension on each spring block Turn control rods in or out until neutral is obtained on each hydrostat Re tighten lock nuts and tension bolts on spring blocks 5 Forward travel speed adjustments Stop engine move levers to drive position lightly push each upper control lever forward until a resistance is felt on the lever At this time check that the forward lever stops on the bottom of each lever are hitting the stop blocks If adjustment is required loosen the lock nuts on the lever stop and turn the bolt in until the lever hits the stop block before resistance is felt in the hydrostat See Figure 4 6 Balance of travel speed If mower tends to pull to either side readjust lever stop on fast side to slow the hydrostat down and even out the ground speed DO NOT SPEED UP THE SLOW SIDE AS OVER STROKING OF THE HYDROSTAT COULD RESULT IN DAMAGE TO THE UNIT If upper control levers are slightly off set following this adjustment they can be realigned by bending them slightly Refer to the diagrams on the following pages for the location of adjustment points TURN ROO AS REQUIRED TO 1 PROPE PULLEY TRAVEL REAR OF MACHINE TIGHTEN OR LOOSEN NUT AS REQUIRED TO CENTER BELT ON PULLEY Figure 2 BRAKE LINK TIGHTEN OR LOOSEN NUT TO ADJUST BRAKE THREADED E
16. e 34 5643 5644 5645 5648 5649 5650 5651 6065 6075 6100 6101 6109 6111 6168 6236 6260 6263 6264 6272 6282 6283 6293 6297 6366 6370 6392 6744 7015 7594 7647 7648 7649 8167 8244 8384 8386 8389 8390 8393 8394 8395 8429 8452 8455 8457 Input Gear GB Bearing Gearbox Bearing Spacer GB CW Fan Machined CCW Fan Machined Hydro Hydro Serpentine Idler Spring Engaging Idler Bracket Spacer Outer Shaft Key Center shaft Key Serpentine Blade Drive Belt Deck Drive Belt Trash Guard Mower Blade 42 Standard Blade Washer Hub Spacer 459 Deck Hub Machined V Pulley Tapped Shaft Weldment Long Tapped Shaft Weldment Short Deflector Mount Bracket Deflector Pin Mower Deck Weldment Mower Deck Assembly Blow By Baffle 42 Spring L Rod 7 Thrust Bearing Wheel amp Tire Assembly Caster Axle RH Caster Axle LH Caster Wheel Bearing Clutch Kit Upper Body Lower Body Frame Assembly Front Rim Black 3 8 Black Hose 3 75 3 8 Black Hose 28 5 Wire Kit Oil Valve Hose Assembly Battery Cover Serpentine Idler w Stud Deflector w Decal 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 Tank Cover 9142 Lift Rod Rear 9156 Right Swivel Plate 9157 Left Swivel Plate 9158 Control Lever
17. e electrical system not functioning correctly Engine being operated at too low an RPM Low battery condition Poor connections on clutch switch Broken wiring REMEDY Push button to reset Consult your dealer for repair Charge battery Tighten or replace as required Have electrical system checked by your dealer Increase engine RPM Contact your dealer for information Repair or replace as required Consult your dealer for repair NOTE Electrical system failures are generally simple in nature always check the obvious first and then move onto the more complicated parts used Poor battery service loose connections corrosion frayed or broken wiring are more likely than component failure Page 24 5 009 0333 05 102 L zte 25 2 6 435113 2181 7 GER 26 49089 933 03 695 102 Lrs 25 1205 13811 21 1 55 GEES 8516 216 56 500 200 55 Ze 2595 1096 5 t8 Page 26 SIEISOIDAH pue 8 1 1276 27 21942373 OL 4 18 35656 YaMOW 21417207 416 1317 9 29 3688
18. hreaded adjuster up or down until both side to side measurements are equal Retain measurement D Rotate or turn both outer blades to align with the deck in front to rear manner Move to the left rear threaded adjuster left rear is designated from operator position on the mower Turn adjuster nut up or down until rear of mower deck is positioned level to 1 8th of an inch higher than the side to side measurement At this time the mower deck will hang or be suspended on 3 points Move the right rear adjuster and take out the slack which will be present by turning adjuster lock nut up Confirm the measurement used on the left rear of the deck NCTEThis will place the mower deck in a base measurement position Additional adjustment may be required to achieve desired cut for the type of grass or conditions being mowed DECK LEVELING ADJUSTMENT POINTS Page 10 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 low 4 Trickle charge battery using a charger of less than 6 amps until all cells are gassing freely Hydrometer readings may be taken if desired 5
19. hrough lift frame and tabs on mower deck Install hair pin clips on front and rear of support rods 5 Move lift lever to lowest cut position install engine to mower deck drive belt on top center pulley Check belt routing after installation to make certain that belt is centered in groove of electric clutch pulley 6 Move lift lever toward high cut position and remove brake link from hole on lift lever 7 Install front body connect headlight wiring FRONT HANGER ROD REAR HANGER DECK SUPPORT ROD LIFT PLATE LAN Page 9 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 correct stance Inflate tires as required Front 19 21 lbs maximum Rear 10 14 158 maximum B Rotate or turn each outer blade tip to align with the edge of the deck or side to side C Measure from the surface up to the bottom of the blade tip on the discharge side of the mower deck Retain this measurement Move to the opposite side check that measurement is the same If adjustment is required turn the nut on the bottom of the front t
20. mower wiring harness which is located on the right side of the mower frame 2 multi meter 1 and attach two leads to the two gt wires coming from the electric clutch WN P 3 The reading you receive should be between 2 4 to 2 9 OHMS 4 the resistance is outside this range the clutch coil is faulty 5 If the clutch coil is faulty the clutch must be replaced Page 15 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 move front belt access cover from body Stand in front of mower grasp lift quadrant lever with left hand Move lever to align with the 5th hole from the bottom on the quadrant plate At this time connect brake link into hole on lift lever Move lift lever toward lowest cut position and remove belt from the top of center deck hub assembly nove the hair pin cotters from the ends of the deck support rods Slide deck support rods from deck while supporting deck assembly with a suitable brace or by the use of an assistant to hold the deck while rods
21. ontrolled 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 Located on control panel to operators right THROTTLE CONTROL LEVER Controls engine speed slow to maximum Lever should be set to the maximum or wide open setting to insure adequate cooling of the engine and to maintain mower deck blade speed while mowing MOWER DECK CUT HEIGHT LIFT LEVER Controls the cutting height of the mower deck Seven positions of adjustment in which the very top or highest notch is used for transporting the mower ina non mowing situation Located in front of operator on the right side of mower BLADE DRIVE To engage the mower deck cutter blades lift switch up lightly and push forward To disengage blades pull switch backward Switch is clearly marked on and CIRCUIT BREAKER Protection of the electrical system is by 1 15 amp circuit breaker If circuit breaker engages push button to reset If this condition repeats consult dealer for inspection and repair Page 13 AND 5421 This portion of the Model 5421 owners manual deals with normal service items which can performed by the owner Please remember that if you are in doubt as to the correct service procedures to be followed these and o
22. other express warranty Implied warranties including those of merchantability and fitness for 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 DATE OF PURCHASE Model en DN Owner s Dealership Address Address Owner s Signature Dealer s Signature SEE DEALER FOR DETAILS Page 4 CHASSIS BODY SEAT MOWER DECK BLADE DRIVE DRIVE SYSTEM ENGINE STARTING SYSTEM TIRES CAPACITIES DIMENSIONS NOTE SPECIFICATIONS 11 GA rectangular tube 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 Designed for operator comfort by use of high density closed cell foam padded back and arm rests Seat is adjustable fore and aft 13 GA stamped steel construction 3 blades 42 cut width cut height approximately 1 to 4 7 position lift handle Electric clutch 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 permanently lubricated using a special grease which completel
23. r 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 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 Belts chains sprockets cutting blades 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 7 There is no
24. r 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 Watch out for traffic when crossing or near roadways Keep the mower in good operating condition and keep safety devices in place and working Keep all nuts bolts and screws tight to be sure the mower is in safe working condition To reduce fire hazard keep the engine free of grass leaves or excessive grease 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 When mowing proceed as follows Mow only in daylight or in good artificial light Shut the engine off when removing the grass catcher or unclogging chute Check the blade mounting bolts for proper tightness at frequent intervals Never operate the machine when using medication or under the influence of alcohol or drugs 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 o
25. 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 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 D Wear appropriate safe clothing when mowing close fitting jeans or slacks heavy leather or safety shoes with rough soles Never operate this mower with bare feet or open sandals Do not operate on wet or slippery grass Always mow at the slowest speed that will cut satisfactorily Keep hands and feet away from the blade at all times Keep persons clear of the discharge chute Do not operate mower unless deflector is in place When mowing hills or slopes use extreme caution Reduce speed do not make sudden starts stops or turns Always disengage blades before taking the mower across walks or objects that project above the surface Stay alert for holes rocks and roots in the terrain
26. s and low water pressure A stiff brush can be used to loosen excess grass and dirt build up Avoid directing water pressure onto the mower deck hub assemblies electrical wiring and engine components such as air filter openings To remove excess water which accumulated during washing of the mower either blow off with compressed air if available or start the engine allowing a long enough operation time to dry thoroughly It is advisable to engage the mower deck for a short time to disperse all water from pulleys and belts PLEASE HELP PROTECT THE ENVIRONMENT BY AVOIDING ALL CHEMICALS WHICH MAY DAMAGE OR CAUSE HARM TO PLANTS AND ANIMALS IN YOUR AREA 22000552 eaa 21 MOWER CUT QUALITY TROUBLESHOOTING 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 Your Dixon ZTR Dealer is also available to provide assistance to you SITUATION Poor cut quality Poor cut quality Poor cut quality Poor cut quality Poor cut quality Poor cut quality Poor cut quality Poor cut quality CAUSES Ground speed Loose belts Engine RPM too low Dull or bent
27. th Lock Washer 1 4 Int Tooth Lock Washer 5 1 6 18 X 1 3 8 HH Bolt GR5 3 8 24 X 1 1 4 HH Bolt GR8 w Nylok 5 16 18X1 Soc Head Bolt 5 16 Int Tooth LW 8 18X3 8 Phillips Pan Hd 1 2 13Thin Profile Nylok Washer 51 5 X 874 X 031 Foam Pad 5 16 18Thin Profile Nylok 3 8 16X 2 1 4 HH BoltGRS Idler Shock Mount 5 16 18X 8 HH BoltGRS 5 16 18 X 5 1 2 HH Bolt 3 8 16 X 3 12 HH Bolt 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 Drum Keyed Link Brake Link Right Brake Link Left Control Pivot Shaft Adjustable Collar Control Arm Bracket Neutral Adjust Collar Spacer 1 2 OD X 1 4 Hose Fitting Hose Fitting Elbow Male Adapter Male For 3 8 ID Hose Adapter Male For 5 8 ID Hose Tee Cast Filter Head Oil Filter Tab Hose 5 8 X 14 Hose Guard Spring Tank Cap Gearbox 3 8 Hose 5 5 8 Hose 2 Reservoir Assembly Brass Ferrule G Box Mount Spacer Pag
28. ther 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 Current service requirements will necessitate replacement of an entire hydro unit if failure should occur MAINTENANCE SCHEDULE To insure a long and trouble free service life on all the components used on the Model 5421 a regular and thorough maintenance schedule should be followed As with any type of precision made equipment a certain amount of initial bedding in or seating of the components will take place The following items should be checked after the first 10 hours of operation and on a weekly basis or each 40 hours of use Drive system belts and controls Mower deck belts Tire pressures Hydrostat oil Tightness of all nuts and bolts Electric blade clutch air gap setting Refer to Page 15 for details Refer to engine service manual provided with your mower for maintenance schedules procedures to be used on the engine Page 14 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
29. w Grip Left 9159 Control Lever w Grip Right 9164 Brake Plate 9165 Brake Plate 9171 Spacer 1 75 9172 Spacer 1 50 9174 Brake Rod 9191 Connecting Link 9196 Plate 9212 Spring Belt Tensioner 9268 Spacer 1 25 1 14 9280 Engine Plate 9312 Bumper Weldment 9325 Seat Frame Weldment 9329 Tie Bar Weldment 9330 Bar Weldment 9332 Spring Anchor 9334 Pulley Mount Plate 9335 Pivot Shaft 9336 Pulley Shaft 9339 Rear Wheel amp Tire 9342 der Tube Weldment 9344 Angle Weldment 9346 Engine Plate Weldment 9347 Idler Spring Plate 9350 Brake Shaft Weldment 9372 Body Brace 9374 Brace 9377 Brake Lever 9618 Lift Handle Weldment 9623 Lift Cam Drilled RH 9624 9634 9646 9655 Lift Cam Drilled RH Lift Frame Weldment Lift Plate Lift Shaft Weldment Page 35 36 NOTES NOTES EES 37 38 5 DIXON INDUSTRIES INC A BLOUNT COMPANY AIRPORT INDUSTRIAL PARK PO BOX 1569 COFFEYVILLE KS 67337 0945 316 251 2000 FAX 316 251 4117
30. y 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 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 Electric by key switch operation with safety interlocks on parking brake and blade drive clutch Front 1 1 X 4 10 X 4 smooth profile Rear 1 8 X 9 5 X 8 turf savers 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 Width 51 Height 45 Length 72 Weight 615lbs Additional information provided in service instructions under the individual component SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE Page 5 6 SET AND SERVICE 4 9 Seat Assembly Instructions 2 Upper Control Lever Installation 3 Mower Deck Installation 4 Deck Leveling 5 Final Preparation SEAT ASSEMBLY INSTRUCTIONS 1 Assemble one arm rest bracket to arm rest cushion using 2 5 1
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