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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