Dixon | ZTR423 | Operator`s manual | Dixon ZTR423 Operator`s manual

Dixon ZTR423 Operator`s manual
OPERATOR'S MANUAL FOR ZTR-421, 422, 423 MOWER
ONE-YEAR LIMITED WARRANTY
This lawn mower is warranted for one( 1) year from date of delivery against all defects in materials and workmanship. Lawn
mowers used for commercial service are warranted for 30 days from date of delivery. (Lawn mowers other than those used only
at residence of owner are considered as commercial service.)
Each new mower is warranted against manufacturing defects in material and workmanship under normal use and service. Our
obligation, under this warranty, shall be limited to the replacement to the original retail purchaser of any part or parts, which,
within the warranty period, shall be shown to be defective due to faulty workmanship or materials at the factory. All parts
claimed defective must be returned to the factory for inspection, repair, or replacement with transportation charges prepaid.
This warranty does not apply to damage in transit or damage caused by misuse, negligence or accident, to alterations or
repairs done outside the factory or authorized service stations, nor does it obligate us to assume any transportation charges in
connection with the replacement of parts claimed to be defective.
Our warranty does not apply to the blades, adapters, chains or belts on our mowers due to the very nature of the function-they
perform and to the elements they are exposed to.
The warranty specifically excludes engines, tires, and batteries which are warranted separately by their respective manu facturers. All claims for def ective engines or engine parts must be made in accordance with the engine manufacturer's
warranty.
We reserve the right to make changes in design and changes or improvements on our product without imposing any
obligation upon ourselves to install the same on products heretofore manufactured.
This warranty is null and void if any parts other than original manufacturer's parts are used. There is no other express
warranty.
IMPLIED WARRANTIES, including those of merchantability and fitness for a particular purp ose, are limited to one(1) year
from purchase and, to the extent permitted by law, any and all implied warranties are excluded.
IMPORTANT!
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. Your
Dixon dealer will gladly provide
a check-out ride, and answer
any questions.
READ CAREFULLY
You have purchased a top quality lawn mower that has been inspected at the factory and found to be in perfect mechanical
condition. This lawn mower is warranted for 1 year from date of delivery against all defects in materials and workmanship. Lawn
mowers used for commercial service are warranted for 30 days from date of delivery.
SERIAL NUMBERS
The lawn mower has two serial numbers:
Mower Number — Located on frame at right rear transaxle mount. Transaxle Number — Located on transaxle.
SAFETY INSTRUCTIONS
BEFORE MOWING:
1. Discuss proper maintenance with your Dixon dealer, to
save money and prevent injury. Consult your dealer be fore removing any parts.
2. Don't allow anyone to operate your Dixon mower without
proper instruction. Young children should never be allowed to operate any power mower, riding or walking.
3. Before mowing, pick up all debris — particularly stones
and sharp objects.
4. Before starting the engine, make sure the gas cap is in
place.
DURING MOWER OPERATION
1. The revolutionary Dixon mower attracts many admiring
neighbors. But when mowing, all persons — especially
children — and pets should be cleared from the mowing
area.
2. Wear appropriate, safe clothing when mowing — closefitting jeans or slacks and heavy leather or safety shoes
with rough soles. Never use any kind of mower with bare
feet or open sandals, not even an old push-type model!
3. When grass is wet or slippery, do not use any riding mower.
4. Always mow at the slowest speed that will cut satisfactorily.
5. Keep hands and feet away from the blade at all times.
6. Although the Dixon mower is equipped with a missile
deflector which directs downwards all blade propelled
objects, keep persons clear of the discharge chute.
7. Your Dixon mower is very stable because of i ts low center
of gravity and weight biased to the rear; however, caution
should be exercised when mowing hills or slopes with any
mower.
8. Always disengage blades before taking the mower
across walks or objects that project above the surface.
9. When the mower is not in use, turn the engine off; 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.
10. Before adjusting your mower or adding fuel, turn the engine
off. Let it cool, and disconnect the spark plug so the engine
cannot start by accident. Be sure all moving parts are
stopped.
11. Never run the engine indoors; the fumes are dangerous.
12. Before backing your Dixon mower, stop, turn around, and
look.
13. Gasoline fumes are explosive; use only approved gasoline
containers to store small amount of fuel. No special oil/gas
mixtures are needed for your Dixon mower.
14. If the mower should start vibrating, stop the engine
immediately and check for damage or loose parts. Vibration is usually the warning of trouble.
15. Never lift lawn mower by the body; lift only by the frame.
ALWAYS SET PARKING BRAKE AND DISENGAGE BLADE OPERATION BEFORE DISMOUNTING
IMPORTANT OPERATING INSTURCTIONS
Dixon ZTR mowers offer a new concept in mowing, providing
unique maneuverability and ease. The following procedures will
allow one to become familiar with the unique method of control
very .easily.
1. SET PARKING BRAKE — Be sure that drive levers are
free. (When drive levers are released, they will return to
neutral position.)
2. Move "Blade Operation" lever to "Disengage" position.
Engine will not start when blades are engaged.
3. Move throttle control to "Choke" position.
4. To start models with electric starting, simply insert ignition
key and turn to the far right position. When the engine
starts, release the ignition key and it will remain in the
"RUN" position. To stop the engine simply turn the key to
the "OFF" position.
NOTE: Electric start models are also equipped with manual
start provision. To start engine manually turn switch to "RUN"
and pull the starter rope. To start manual start models, turn
switch to "RUN" position. A sharp pull will start the engine.
Release the start-
ing rope as soon as engine starts. To stop engine turn key
to "OFF" position.
5. Set engine to desired speed by adjusting throttle control.
(Suggest set at slow speed during initial operation.)
6. NOTE SAFETY FEATURE: Engine stops automatically if
operator leaves seat while blades are engaged.
7. This unit is equipped with a unique transaxle that requires
only two drive levers to control braking, turning, direction
and acceleration. TO GO FORWARD:
From neutral position push both drive levers slightly forward; to increase speed move levers further forward. TO
GO BACKWARD:
From neutral position pull both drive levers slightly
rearward. TURNING:
Turning is controlled by moving one drive lever slightly
forward or rearward of the other. To turn left, move left
lever rearward of right lever. To turn "square corners" 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.
BRAKING:
To brake mower, move both levers in direction opposite of
travel, release levers to neutral, set parking brake. When
stopping on incline, it may be necessary to hold slight
pressure on levers in direction opposite of slope, until
parking brake is set.
ALWAYS SET PARKING.BRAKE BEFORE DISMOUNTING.
INITIAL OPERATION:
It is recommended that first operation of mower be done at
a slow setting of throttle speed and disengagement of
mower blades until operator is thoroughly familiar with the
unit.
You may have tendency to "over control" mower at first.
Slight movements — fingertip control — is all that's
necessary for easy operation. 8. Mower Blade Operation:
• Cutting height is set by positioning the adjustment lever.
Push button knob on top of lever, set desired cutting
height, lock into position by releasing button knob.
• To start mower blades, move lever on floor to "engage"
position. To stop mower blades, move lever to "disen gage" position.
ALWAYS DISENGAGE BLADE OPERATION BEFORE
DISMOUNTING.
9. Parking Brake:
Parking brake is on right hand side of floor area and is
engaged by pushing full forward with foot. To disengage,
pull lever back toward operator by hand. In emergency
situations, brake may be used in conjunction with the
natural braking of the transaxle by applying pressure with
foot. Always set parking brake before dismounting. Be
sure that parking brake is disengaged before moving.
MAINTENANCE
PRE-STARTING INSTRUCTIONS
1. Fill fuel tank with a good grade of regular gasoline. Do not
mix oil with gasoline.
2. Attach the spark plug wire to the spark plug.
3. With mower on a level surface, fill the crankcase with a
good grade of multi-purpose 1 0 - 3 0 oil as outlined in the
engine instruction manual.
4. On model equipped with a battery be sure the battery is
filled to proper fluid level with electrolite solution. After
initial filling, level may be retained with distilled water.
CAUTION:
5. During initial "Break In" period, the oil level should be
checked often.
6. Check oil level every five operating hours or each time
mower is used.
7. Change oil every 25 operating hours or sooner if equipment
is operated in extremely dusty conditions.
BELT ADJUSTMENT
Main Drive Belt - This belt should be kept taut to lengthen belt
life and prevent loss of power. To tension belt, loosen 4 bolts
which hold the engine to the mount and the lock nut on the
tension bolt at the rear of the machine. Tighten tension bolt until
belt is taut and retighten the 4 bolts holding engine and tighten
tension bolt lock nut.
MOWER DRIVE BELT
Belt tension for the mower drive belt is adjusted by turning the
turnbuckle to provide more forward movement of the engaging
idler.
REPLACE BELTS WHEN ADJUSTMENT CAN NO LONGER
BE MADE SATISFACTORILY OR IF BELTS BECOME
WORN.
BODY REMOVAL
A. ZTR-421 Body Removal
1. Disconnect throttle cable from engine.
2. Disconnect key switch wire loom from frame wire loom
at front of body.
3. ^Disconnect seat switch wire loom from frame wire
loom. This connection is located approximately level
with the back of the seat on left hand side of frame
under the body.
4. Remove four control lever bolts and remove upper
control levers.
5. Remove engaging handle by removing bolt and nut
under handle.
6. Disconnect brake pedal from brake pedal arm by
removing the two bolts.
7. Remove two acorn nuts on front floor and the two sheet
metal screws in transaxle body mount. This also
removes the two brake arm clips. Body will lift clear. To
replace body reverse the above procedure. When
reinstalling the two screws in transaxle body mount,
make certain brake arm retainer clips extend downward
and are parallel with body mount.
B. ZTR-422 Body Removal
1. Disconnect throttle cable from engine.
2. Disconnect two wire loom plugs, one going to engine
wires and one going to switch. Plugs are located
between back of transaxle mount and battery.
OMIT STEP (3) AND FOLLOW ZTR-421 BODY REMOVAL
INSTRUCTIONS FROM STEP (4) ON. REMEMBER TO
REINSTALL SWITCH GROUND WIRE ON LEFT REAR
TRANSAXLE BODY MOUNT SCREW.
C. ZTR-423 Body Removal
1. Disconnect throttle cable from engine.
2. Disconnect terminal running from motor terminal on
switch to frame loom.
3. Disconnect seat switch plug from frame loom. This plug
is located approximately even with back of seat on left
hand side of frame under body.
FOLLOW ZTR-421 BODY REMOVAL INSTRUCTIONS
FROM STEP (4) ON. REMEMBER TO REINSTALL
SWITCH GROUND WIRE ON LEFT REAR TRANSAXLE
BODY MOUNT SCREW.
CHAIN ADJUSTMENT
To adjust the drive chains, the body must be removed and shims
added behind the transaxle. Loosen 4 bolts which hold the
transaxle to the frame. Insert shims (Pt. No. 1541) as needed for
adjustment between transaxle and mount plates. Tighten the 4
bolts which hold the transaxle to the frame. A few drops of oil
periodically will lengthen chain life. Replace chain when rollers
become loose, chain breaks, or chain fails to operate properly.
WHEELS AND TIRES
Correct tire pressure is essential to the correct operation of the
machine. The correct pressure for the drive tires is 8 -10 Ibs.
The front tires should be inflated to 30-35 Ibs. Lug nuts should
be checked periodically.
ELECTRICAL SYSTEMS
Keep all connections clean and tight. Maintain the fluid in the
battery at correct level.
BODY
The body may be washed with a mild detergent and waxed with
any automotive type wax.
ENGINE
Follow the manufacturer's instructions as to maintenance and
repair.
TRANSAXLE
For adjustment or repair confer with authorized Dixon dealer
service department. Adjustment or repair by other than
authorized dealer voids warranty.
SERVICE LEGS
Service legs are located under the front end of the body of the
unit. These legs serve as additional weight for the front end of
the mower, and when lowered, give service access to the
mower deck without having to remove this assembly.
To lower these service legs:
1. Set parking brake.
2. Raise mower deck to top position.
3. For safety, support the service legs so that they will not fall.
Loosen and remove the four nuts and two bottom plates
from the U-bolts. Then remove the support and lower
service legs to ground.
4. Raise front end of unit and move the service legs into
position, spreading them as wide as possible to achieve
maximum stability.
SPARE PARTS
See your dealer for ordering spare parts or warranty service.
INSTALLING AND REMOVING MOWER DECK FROM FRAME
1. Attach stabilizer arms to mower deck with
.
pins and clips as shown on drawing.
2. Attach the 1/2" dia. engaging rod with a
rollpin through the engaging cam.
3. Position the drive belt on pulleys.
4. Place mower deck under unit in approximate
operating position with engaging rod through
hole in the floor.
5. Connect drive belt to motor pulley, being
certain that belt is inside of belt guides.
Loosen belt keeper by loosening the two rear
engine mount bolts; this will allow belt to be
placed on motor pulley. Retighten engine
mount bolts.
6. Attach stabilizer arms to pivot point on the
inside of attaching plates with pins and clips.
7. Attach lift linkage to mower deck on the inside
of the attaching lugs as shown on drawing
with pins and clips. (4 places)
8. Place engaging handle on eng aging rod and
fasten with bolt and locknut.
9. Connect pan wire loom plug to plug on frame
wire loom. Mower will not start unless this
connection is
made. To operate mower with pan removed an available by-pass (P/N 4038) must be used.
BODY ASSEMBLY
CHASSIS ASSEMBLY
TRANSAXLE ASSEMBLY
MOWER DECK ASSEMBLY
PARTS LIST
Part No.
Name
1000 Frame Weldment (Electric)
1015 Caster Assembly
1020
Caster Axle
1022 Caster Wheel & Tire
1029L Lift Lever & Quadrant Left
1039
Lower Lift Link
1040
Lift Tie Rod
1043
Battery Strap
1100 Frame Weldment (Manual)
1500 Lower Control Lever
1501R Upper Control Lever Right
1501L Upper Control Lever Left
1502 Control Rod Assembly
1504
Wheel Hub & Sprocket
1507
Wheel Bearings
1509 Wheel& Tire
1528
Bellcrank
1535
Chain
1536
Connecting Link
1538
V-Pulley
1539
Drive V-Belt
1540
Key
1541
Shim
Part No.
Name
1542
V-Pulley
1543
Lift Knob
1552
Belt Keeper
1560
Battery Splash Guard
1564
Brake Arm 75 Model
1567
Brake Mount 75 Model
1574
Brake Pivot 75 Model
1579
Short Brake Rod 75 Model
1580
Long Brake Rod 75 Model
1581
Brake Pedal Arm 75 Model
1584
Brake Pedal 75 Model
1
3025
/4 x 1 Spiral Pin
1
3026
/4 x 1 1/2 Spiral Pin
3029
Front Grommet
3030
Rear Grommet
3054
3/16 x 1 Roll Pin
1
1
3070
/4 x 1 /4 Spiral Pin
3501
Nylon Bushing
3502
Hand Grip
3504
Double Ball Joint
4002
Deluxe Seat 36", ZTR-421
4003
Headlight
4004
Switch
Part No.
Name
4005
Throttle Cable
4006-1 Battery Solenoid Cable
4006-2 Battery Ground Cable
4006-3 Solenoid-Alternator Cable
4006-4 Swith-Headlight Cables, ZTR-421
4006-5 Front Loom Assy. Prior to 75
4006-6 Rear Loom Assy. Prior to 75
4006-7 Rear Loom Assy., ZTR-422
4007
Battery
4008
Solenoid
4009
Wire Clip
4010
Control Decal
4011
Name Decal
4014
Standard Seat 18"
4025
Switch Decal
4027
Pan Loom ZTR-421, ZTR-422
4028
Frame Wire Loom, ZTR-422
4029
Switch Wire Loom, ZTR-422
4030
Seat Switch Wire Loom, ZTR-421
4031
Frame Wire Loom, ZTR-421
4032
Pan Wire Loom, ZTR-423
4033
Frame Wire Loom. ZTR-423
4034
Switch Wire Loom, ZTR-423
Part No. Name
Part No.
4035
4036
4037
4038
4050
4051
5000
5003L
5003R
5004R
5004L
5005
5006
5007
5009L
5009R
5010R
501OL
5011
5012
5013
5014
5015
5016
Name
Switchground Wire, ZTR-423
Micro Switch
Front Wire Loom, ZTR-421
Pan By-Pass Plug
Body-White
Body - Blue
Transaxle
Support - Left
Support - Right
Support Assembly Right
Support Assembly Left
Discup
Spacer
Center Frame
Cradle - Left
Cradle - Right
Cradle Assembly Right
Cradle Assembly Left
Support Shaft
Cradle Shaft
Frame Shaft
Torque Rod
24 T Sprocket
Cone
5018
5019
5021
5022
5023-1
5024
5025
5028
5028-A
5035
5036
5044
5050
6025
6050
6052
6055
6058
6059
6060
6063
6065
6070
6075
9 T Sprocket - Narrow
Chain
9 T Sprocket - Wide
Thumb Screw
Pivot Bolt
Cradle Spring
Frame Assembly
Bearing
Bearing - Notched
Transaxle Pulley
Pivot Spring
Torque Rod Stiffner Kit
Positive Neutral Kit
Mower Deck Assembly
Mower Deck Weldment
Stabilizer Arm
Mower Bearing
V-Pulley
Flat Idler Pulley
Serpentine Idler Bracket
Bronze Bushing
Tension Spring
Engaging Idler Bracket
Spacer
Part No.
6077
6078
6086
6087
6088
6089
6092
6093
6094
6095
6097
6100
6101
6107
6108
6109
6110
6111
6112
6113
6119
6127
6130
Name
Bearing Spacer
Pulley Spacer
Connecting Link
Engaging Rod
Turnbuckle
Engaging Handle
Blade
Outer Hub Assembly
Hub
Center Shaft Assembly
Outer Shaft Assembly
Key
Key
Pin
Center Hub Assembly
V-Belt
V-ldler Pulley
V-Belt
Engaging Spring
Blade Washer
Decal
Deflector Assembly
Engaging & Switch Cam 75
OWNER INFORMATION
Date Mower Purchased ______________________ Mower Model Number_____________________________
Mower Purchased from ______________________________________________________________________
dealer name & address
Mower serial number ____________________________ Transaxle Serial Number_______________________
Oil changed this date:
1. _______________________________________
2. _______________________________________
3. _______________________________________
4. _______________________________
5. _____________________________
6. _____________________________
Engine tuned this date:
1. _______________________________________
2. _______________________________________
3. _______________________________
4. _______________________________
® Dixon and ZTR are the trademarks of
FORM NO. 812-476
Dixon Industries Inc. Box 494 Coffeyville, Kansas 67337
LITHO IN U.S.A.
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