Dixon 5421 User Manual

IMPORTANT - READ CAREFULLY

The Dixon ZTR Mower is both easy and fun to operate. However, any power mower must be operated properly to be safe. It is not a toy or a recreational vehicle. Before you start to use the mower, read the operator's manual carefully, and become completely familiar with the controls.

The information in this operator's manual applies to all Dixon ZTR Model 5421 Mowers. Your Dixon dealer will gladly provide a check-out ride, and answer any questions.

See your dealer for warranty service, parts and repairs.

DIXON INDUSTRIES, INC A BLOUNT COMPANY AIRPORT INDUSTRIAL PARK PO BOX 1569 COFFEYVILLE KS 67337 O945 316 251 2OOO FAX 316 251 4117

INDEX

1. SAFETY ............................................................... Pages 1- 3

2. WARRANTY POLICY........................................... Page 4

3. SPECIFICATIONS ............................................... Page 5

4. SET UP AND SERVICE ....................................... Pages 6 -11

5. OPERATION INSTRUCTIONS............................. Pages 12 - 3

6. CARE AND MAINTENANCE ................................ Pages14- 21

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

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

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

SAFETY

The operator or bystander inserts a hand or foot into the discharge chute

path of the cutting blade. Never

run the mower blades when there are people nearby. Always turn the

over or backed over by 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,

watched by

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

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

offs, especially if they are

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

bystander. To prevent this from

happening, never remove the safety discharge chute from the mower

fueling of the rnower or

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

which

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

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

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:

operator or bystander...

or under the mower deck and into the

engine off when cleaning or working around the mower deck.

This situation occurs when a bystander is runmower. The

especially children. Young children should be indoors and an adult. Always look behind you before backing up.

a drop-off. Mow across the slope

slope you can't back up". Stay clear of dropon the down side of a slope.

which can be hurled into the path of a

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

5. FIRES:

6. OPERATION BY CHILDREN:

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.

Most accidents of this type occur during re-

related engine components operate at very high temperatures

cool before re-fueling or placing in storage.

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

Page 1

SAFETY

SAFETY REMINDERS: READ CAREFULLY BEFORE OPERATION

1. Wear appropriate, safe clothing when mowing - close fitting jeans or slacks and heavy leather or safety shoes with rough soles. Never operate this mower with bare feet or open sandals.

2. Do not operate on wet or slippery grass.

3. Always mow at the slowest speed that will cut satisfactorily.

4. Keep hands and feet away from the blade at all times.

5. Keep persons clear of the discharge chute. Do not operate mower unless deflector is in place.

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

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

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

drop-offs.

9. When the mower is not in use, turn the engine off and remove key. Never leave the engine running unattended. Your Dixon mower is equipped with a weight-sensitive switch that kills the engine when operator leaves the seat while blades are engaged.

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

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

10. Before adjusting or servicing your mower, turn off the engine and let it cool. Be sure all moving parts are stopped. Never run the 5421 with the body open.

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

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

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

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

an engine that has not been allowed to cool after running. Never fill the tank indoors and always clean up spilled gasoline.

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

fumes may reach an open flame or spark. Allow the engine to cool before storing in any enclosure.

Page 2

B. Limit loads to those you can safely control.

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

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

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

ohol

SAFETY REMINDERS:

(Continued)

14.

15.

16.

17.

18.

19.

20.

21.

22.

Never lift lawnmower by the body, lift only by the frame.

Never carry passengers.

Use care when pulling loads or using heavy equipment.

A. Use ONLY approved drawbar hitch points.

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:

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

or drugs.

Page 3

DIXON LIMITED WARRANTY POLICY -- HYDRO-GEAR MODELS

This warranty policy applies to all Hydro-Gear mowers or any 50" model, purchased on or after March 1,1990.

WARRANTY: Dixon Warranty term is for a period of one (1) year from date of purchase or 400 hours of use, whichever occurs first. Mowers used for residential homeowner applications (used only at owner's primary place of residence) are warranted for two (2) years from date of purchase or 400 hours of use, whichever occurs first. DIXON ZTR MOWERS ARE WARRANTED AGAINST DEFECTS IN MATERIALS AND WORKMANSHIP AND PROVIDES FOR REPLACEMENT OR REPAIR OF PARTS INCLUDING LABOR COSTS. THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS AND LIMITATIONS:

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

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

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

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

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

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

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

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

(a) Pick up and delivery charges for transportation of mower to and from an Authorized Dixon Dealer's place of business. (b) Routine maintenance or adjustments. (c) 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.

There is no other express warranty. Implied warranties, including those of merchantability and fitness for a particular purpose, are limited to the same duration of the express warranty, and to the extent permitted by law any and all implied warranties are excluded. Liabilities for consequential damages under any and all warranties are excluded.

Page 4

made of rotational molded polyethylene. Front body contains access

panels for battery service and engine to mower deck belt removal. Rear body

e of high density closed cell foam, padded

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

y lubricated using a special grease which completely eliminates the

1 OL Series 70 hydrostatic transmissions are serviced with

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

Cycle, Air Cooled, Gasoline, Twin

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

with safety interlocks on parking brake and blade

3 quart with inline 10

30 motor

Additional information provided in service instructions under the individual

CHASSIS:

BODY:

11 GA - rectangular tube.

Two piece -

SPECIFICATIONS

tilts up to allow service on the entire drive system.

SEAT:

Designed for operator comfort by us

back and arm rests. Seat is adjustable fore and aft.

MOWER DECK:

BLADE DRIVE:

DRIVE SYSTEM:

13 GA stamped steel construction, 3 blades, 42" cut width, cut height approximately

1 " to 4" via 7 position lift handle.

Electric clutch.

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

permanentl need for any type of maintenance.

The Hydro Gear BDU-

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

ENGINE:

STARTING SYSTEM:

TIRES:

CAPACITIES:

DIMENSIONS:

NOTE:

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

16 HP Kohler Magnum, Vertical Crankshaft, 4-

Electronic Ignition, Full Pressure Lubrication.

Electric by key switch operation 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 micron filter. Hydrostat oil recommendation - name brand SAE 10Woil.

Width 51" Height 45" Length 72" Weight 615lbs.

component.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.

Page 5

SET UP AND SERVICE

Page 6

Seat Assembly Instructions

Upper Control Lever Installation

Mower Deck Installation

Deck Leveling

Final Preparation

Assemble one arm rest bracket to arm rest cushion using (2) 5/1 6 standard flat washers (3020)

ndard flat washers (3020)

washers

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

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

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

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

SEAT ASSEMBLY INSTRUCTIONS

and (2) 5/16-18 x 1 hex head nylok bolts (3224). Do not tighten hardware at this time.

Assemble arm rest bracket/cushion to seat bottom using (3) 5/16 sta and (3) 5/16-18 x 1 hex head nylok bolts (3224). Do not tighten hardware at this time.

Repeat steps 1 and 2 for other arm rest bracket.

Assemble arm rest brackets and utility box to seat back using (4) 5/1 6 standard flat (3020) and (4) 5/1 6-18x1 hex head nylok bolts (3224). Tighten all seat hardware at this time.

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

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

switch wiring.

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

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

Do not fully on front studs.

Page 7

UPPER CONTROL LEVER INSTALLATION

Raise rear body cover to fully open position.

Install flat washer on right hand swivel plate weldment. Next install right hand control lever, then second flat washer.

Push control lever into the neutral slot and install (2) cup washers, (1) flat washer and jam nut. (See illustration)

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.

Repeat above procedure on left side.

Page 8

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

Loosen and remove front body mounting bolts (P/N 3368) and washers (P/N 3066).

r 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

Raise f

ront of mower deck and slide front support rod through lift frame and tabs on

Move lift lever to lowest cut position, install engine to mower deck drive belt on top center

Check belt routing after installation to make certain that belt is centered in

Page 9

NOTE:

MOWER DECK INSTALLATION

Brake link (P/N

DISCARD cotter pin and washer after engine to mower drive belt has been installed.

Disconnect headlight wiring plug from wiring harness. Lift front body from chassis.

Install rea

1/2 inch of threads are exposed.

Position mower deck under chassis.

mower deck. Install hair pin clips on front and rear of support rods.

pulley. groove of electric clutch pulley.

Move lift lever toward high cut position and remove brake link from hole on lift lever.

Install front body, connect headlight wiring.

Page 10

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 a correct stance. Inflate tires as required: Front - 19 - 21 Ibs maximum Rear- 10 - 14 Ibs 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 threaded 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.

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