Dixon 422 Lawn Mower User Manual

OPERATOR’S MANUAL
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 carefully inspected and adjusted at the factory. 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. SEE YOUR DEALER FOR WARRANTY SERVICE
FOR PARTS.
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 or belts on our mowers due to the very nature Of the function they perform a nd to
the elements they are exposed to.
"
The warranty specifically excludes engines and tires which are warranted separately by their respective manufacturers. All
claims for defective 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 pa rts 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 purpose, are limited to one (1) year
from purchase and, to the extent permitted by law, any and all implied warranties are excluded.
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!
SERIAL NUMBERS
The lawn mower has three serial numbers:
Mower Number — Located on frame at right rear transaxle mount. Transaxle Number — Located on transaxle. Engine
Number — Located on engine. When referring to serial number on Warranty Registration, etc., use Mower Serial Number
located on frame.
SAFETY INSTRUCTIONS
BEFORE MOWING
1. Read these safety instructions and engine manufacturer's
operating and maintenance instructions that are furnished
with the mower.
2. Discuss proper maintenance with your Dixon dealer, to
save money and prevent injury. Consult your dealer before
removing any parts.
3. 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.
4. Before mowing, pick up all debris—particularly stones and
sharp objects.
5. Before starting the engine, make sure the gas cap is in
place.
DURING MOWER OPERATION
1. The revolutionary Dixon mower att racts 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, keep persons clear of the discharge chute. Do not operate mo
7. Use extreme caution 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.
Test this important safety feature before each time mower is
used. 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 your mower or adding fuel, turn the en gine 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 imme diately 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.
16. Never carry passengers.
.
ALWAYS SET PARKING BRAKE AND DISENGAGE BLADE OPERATION BEFORE DISMOUNTING.
IMPORTANT OPERATING INSTRUCTIONS
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 and in the neutral position. (When drive levers are
released, they should return to neutral position.)
2. "Blade Operation" lever is to be set in the "Disengage"
position.
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 remai n in the
"RUN" position. To stop the engine simply turn the key to
the "OFF" position.
NOTE: Some electric start models are also equipped with
manual start provision. To start engine manually
turn switch to "RUN" and pull the starter rope.
5. Set engine to desired speed by adjusting throttle control.
(Suggest set at slow speed during initial operation.)
6. NOTE SAFETY FEATURE: Safety switches stop engine
when operator leaves seat while blades are engaged, and
engine cannot be started when blades are engaged . OPERATOR SHOULD TAKE PRECAUTIONS AND NOT RELY
ON SAFETY SWITCHES.
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 gently push both drive levers forward;
to increase speed move levers further forward.
TO GO BACKWARD
From neutral position gently pull both drive levers
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 throttle setting with mower blades disengaged until
operator is thoroughly familiar with the unit.
You may have a tendency to "over control" mower
at first. Slight movement - 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 in to position by releasing button knob.
• To start mower blades, move lever on floor to "engage"
position. To stop mower blades, move lever to "disengage" 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
BEFORE PERFORMING ANY MAINTENANCE, SHUT
OFF ENGINE, ALLOW TO COOL AND DISCONNECT
SPARK PLUG.
ENGINE
terminal. (See also wiring diagram shown on Body Assembly
illustration.)
3. Clean top of battery and terminals.
4. Do not remove battery from mower.
5. To reactivate, reconnect cables to correct terminals and
charge battery if needed.
BELT ADJUSTMENT
The best tension for a V -belt drive is the lowest tension at
which the belts will not slip under normal load condition. Check
the tension on a new belt frequently during first hours of
operation and every 10-15 hours or monthly thereafter. Too
much tension shortens belt and bearing life. Too little tension
causes slippage and loss of power. Be sure that belts and
pulleys are kept free of foreign material. If belt slippage occurs,
tighten it just enough to prevent slippage.
For complete engine operating and maintenance information, refer to engine operating and maintenance instructions
furnished by the engine manufacturer and supplied with
each mower.
TRANSAXLE DRIVE BELT
To adjust tension, loosen four (4) bolts which hold engine to
mount and belt keeper in place. Adjust tension bolt (located at
rear of chassis) until desired tension is achieved. Do not over
tighten. Tighten four (4) bolts holding engine.
BATTERY
Procedure for initial activation of battery:
1. Fill with electrolyte solution to lower ring of battery.
2. Let stand for 30 minutes.
3. Charge at 4 amps for 3 hours or 1 amp for 12 hours.
4. After initial filling, fluid level may be maintained with distilled
water.
MOWER DRIVE BELT
Belt tension for mower drive belt is adjusted by loosening nut
on mower deck turnbuckle assembly and turning turnbuckle to
achieve desired tension. Retighten nut. Tension should be
checked with belt in engaged position.
Procedure for off-season storage:
1. Charge battery.
2. Disconnect cables from battery terminals. Identify cables so
that they may be easily reconnected to the correct
REPLACE BELTS WHEN ADJUSTMENT CAN NO
LONGER BE MADE SATISFACTORILY OR IF BELTS BECOME WORN.
BODY ROMOVAL ZTR 422 - 424
1. Disconnect throttle cable from engine.
2. Remove four (4) control lever bolts and remove upper control
levers.
3. Remove engaging handle by removing bolt and nut under
handle.
4. Remove the two (2) attach nuts on floor of body and two (2)
sheet metal screws at the rear of body.
5. Disconnect the rear wiring loom from the body by lightly
squeezing the Econo-Seal plug. This plug is located at the
left rear of the body.
6. Note: Loosen bolts that hold safety switch (P/N 4079) mount
plate and slide switch away from engaging rod. Tighten one
bolt just enough to hold switch in this position until body is
reassembled.
7. Place height adjustment lever in vertical position and carefully lift body up and off of chassis.
8. Reverse the above procedure for assembly.
Note: With the mower deck in the engaged position slide
the switch bracket toward the engag ing rod (P/N 6087-1)
until the switch leaf just makes contact with the switch
button. Tighten both bolts in switch bracket. With the mower
deck engaged, attempt to start engine in all cutting height
positions. If engine starts in any cutting height positio n
readjust the switch. Disengage the mower deck and start
the engine in each cutting height position. If engine fails to
start in any cutting height position readjust switch. With
operator in normal mowing position engage mower deck
and remove weight from seat. The engine should die.
Repeat this procedure in each cutting height position.
CHAIN DRIVES
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 as needed for
adjustment between transaxle and mount plates. When
properly adjusted, the slack span at the mid -point of the
chain should have a total possible movement perpendicular
to the chain of about 9/16". Tighten the 4 bolts which hold
the transaxle to the frame. Replace chain when rollers
become loose, chain breaks, or chain fails to operate pro perly.
LUBRICATION
1. Chains: Proper lubrication is important for effective
roller chain operation. Use high quality lubricating oil (do
not use grease or extra heavy oil) and apply drops of oil
to the chain joints every 10-15 hours of operation.
2. Front Caster Assembly: Each caster assembly has a
grease fitting located on the underside of the bearing.
For best results, use any good multi-purpose grease
every 1 0 - 1 5 hours of operation.
3. All other Bearings: All other bearings on your mower
are sealed and require no lubrication.
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 20-24 Ibs. Lug nuts
should be checked periodically.
ELECTRICAL SYSTEMS
Keep ail 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.
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 Vz" 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 lower engine 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 lift linkage to mower deck on the inside
of the attaching lugs as shown on drawing with
pins and clips. (4 places)
7. Attach stabilizer arms to pivot point on the inside
of attaching bracket with pins and clips.
8. Place engaging handle on engaging rod and fasten with bolt
and locknut.
9. After installing pin clips, rotate pins so that open end of clip
is down.
TRANSAXLE
For adjustment or repair confer with authorized Dixon dealer
service department. Adjustment or repair by other than
authorized dealer voids warranty.
SPARE PARTS
See your dealer for ordering spare parts or warranty service.
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I
PARTS LIST FOR 42" MODELS
Part No.
-
1000C
1014
1015
1020
1022
1022A
1039
1043
1093
1094
1095
1501R
1501L
1502
1503
1504
1506
1507-1
1509
1535
1536
1539
1540
1543
1544
1552
1560-1
1564
1574
1579
1580
DescriptionPart No.
Frame Weldment
Caster Pipe Nipple
Caster Weldment
Caster Axle
Caster Wheel & Tire
Caster Wheel Bearing
Lower Lift Link
Battery Strap
Tie Bar Assembly
Tie Bar
Caster Weldment Assembly
Upper Control Lever R
Upper Control Lever L
Control Rod Assembly
Wheel Hub Assembly
Wheel Hub
Hub Flange
Wheel/Hub Bearing
Rear Wheel & Tire
Drive Chain
Chain Connecting Link
Transaxle Drive Belt
Engine Shaft Key
Lift Knob
Bellcrank Assembly
Belt Keeper Weldment
Battery Splash Guard
Brake Arm Weldment
Brake Pivot Weldment
Short Brake Rod
Long Brake Rod
Description
1581
1591
1606
1624
1629
1635
1636
1638
1643
1645
1646
1647
2091
2221
2222
2436
3029
3059
3502
3504
3507
3508
3511
3521
3531
3532
3533
3534
4005B
4006-2
4006-8
"
Part No.
Brake Pedal Arm Weldment
Brake Pedal Pin
Brake Mount Weldment
Oil Drain Assembly
Bumper Weldment
Double Engine Pulley
Bellcrank Kit
Lower Control Lever Assembly
Brake Pedal
Seat Bracket
Weight Brace
Control Pin (replaces 1604)
Tension Bracket
Transaxle Shim 16 ga.
Transaxle Shim 22 ga.
Switch Decal
Front Grommet
Spring Wire Clip
Hand Grip
Double BallJoint
Floor Pad - Long
Floor Pad - Short
Adhesive Bumper
Engaging Cam Mount Bushing
Decal - Operating Instructions
Decal - Blade Drive
Decal - Cutting Height
Decal - Parking Brake (42")
Throttle Cable
Solenoid - Starter Cable
Solenoid - Battery Cable
Description
4006-9 Battery - Ground Cable
4007-1 12 V Battery
4008 Solenoid
4009 Wire Clip (not shown)
4011-1 Name Decal, 42"
4013 Wire Tie
4014 Seat, ZTR 422
4014A Seat Assembly (includes 4054)
4022 Ground Terminal
4025 Switch Decal
4049 Model Decal, ZTR 422
4050 Body, ZTR 424
4051
Body, ZTR 422
4054 Seat Switch Assembly
4058 Arm Rest Bracket R
4059 Arm Rest Bracket L
4060 Arm Rest
4065 Model Decal, ZTR 424
4067 Ignition Switch
4067A Switch Key (for 4067)
4069 Seat Bottom
4070 Seat Back
4071
Seat Assembly
4075
10 AMP Fuse (not shown)
4076 Headlight Assembly
4079 Body Switch
4083 Switch Bracket - Switch Section
4092 Fuse Holder
4093 Body Wiring Loom
4109 Rear Wiring Loom
4112 Body Wiring Loom
Part No. Description
Part No.
4113
Wiring Kit
4114
Wiring Kit
5000
Transaxle
5000-102 Transaxle
5001
Rear Tube Assembly
5002
Front Tube
5003R Support R
5003L Support L
5004R Support Assembly R
5004L
Support Assembly L
5005
Discup
5006
Support Spacer
5007
Cone Frame
5009R Cradle R
5009L Cradle L
501 OR Cradle Assembly R
5010L Cradle Assembly L
5011
Support Shaft
5012
Cradle Shaft
5013
Cone Frame Shaft
5014-1 Torque Rod
5015 - 24 T Sprocket
5016
Molded Cone (each)
5018
9 T Sprocket - Narrow
5019
Transaxle Chain
5021
9 T Sprocket - Wide
5022-1 Thumbscrew
5023-1 Pivot Bolt
5024-1 Cradle Spring
5025
Cone Frame Assembly
5028
5035
5036
5044
5045
5046
5047
5050
5053
5054
5055
5059
5061R
5061L
5065
5066
5068
5069
5070
5073R
5073L
5077
6030-1
6040
6052
6058
6059
6060
6063
6065
Description
Transaxle Bearing
Transaxle V-Pulley
Pivot Spring
Torque Rod Stiffener L
Torque Rod Stiffener R
Positive Neutral Rod
Positive Neutral Spring
Positive Neutral Kit
Brake Arm Retainer
Transaxle Service Tool Kit
Torque Rod Stiffener Kit
Double Bearing
HD Support Assembly R
HD Support Assembly L
HD Cone Frame Assembly
HD Cone Frame Shaft
HD Pulley Spacer
HD Transaxle Pulley
Transaxle Key
HD Support R
HD Support L
HD Cone Frame
Mower Deck Assembly
Mower Deck Weldment
Stabilizer Arm
V-Pulley
Flat Idler Pulley
Serpentine Idler Weldment
5
/16" OD x 3/8" ID Bronze Bushing
Serpentine Idler Spring
Part No.
6070
6075
6077-1
6078
6087-1
6089
6092
6093-1
6094-1
6095-1
6097-1
6100
6101
6107
6108-1
6109
6110
6111
6113
6119
6123
6127
6134
6135
6136
6148A
6151
6154,
8005
Description
Engaging Idler Weldment
Engaging Idler Spacer
Bearing Spacer (use w/6094-1)
Pulley Spacer
Engaging Rod
Engaging Handle
Mower Blade
Outer Hub Assembly (replaces 6093)
Deck Hub Casting
Center Shaft
Outer Shaft
Outer Shaft Key
Center Shaft Key
Deck Pin
Center Hub Assembly (replaces 6108)
V-Belt
V-ldler Pulley
Deck Drive V-Belt
Blade Washer
Caution Decal
Engaging Idler Stud Bushing
Deflector Weldment
Engaging Spring
5
/16" Turnbuckle
Engaging Cam Weldment
Connecting Arm Assembly
Mower Deck Bearing
5
/16" x 1" Rivet
Fiberglass Repair Kit (limited shelf life)
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._____________________________________________
4.__________________________________________
2. _____________________________________________
5. __________________________________________
3. ______________________________________________
6. ___________________________________________
Engine tuned this date:
1._________________________________________
3.____________________________
2. _____________________________________________
4. ______________________________
tho in U.S.A.
DIXON INDUSTRIES, INC. BOX 494, COFFEYVILLE, KANSAS 67337
® DIXON and ZTR are registered trademarks of Dixon Industries,