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 [phone]

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.

B.

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.

7.

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

1.

2.

3.

4.

5.

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

1.

2.

3.

4.

5.

6.

7.

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.

8.

Do not fully
on front studs.

Page 7

1

2.

3.

4.

5.

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:

1.

2.

3.

4.

5.

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.

6.

7.

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.

connecting leads on chassis. Always connect

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 are 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. Install permanent battery caps and wash any accumulated acid from battery before
re-installation on chassis.

6. Observe proper battery polarity when re­positive 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.

Page 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 brake 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 112 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
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.

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 (controlled 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 in a

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 off".

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

CARE AND MAINTENANCE - MODEL 5421

1

.

2. Mower deck belts.

4.

This portion of the Model 5421 owners manual deals with normal service items which can be
performed by the owner. Please remember that if you are in doubt as to the correct service
procedures to be followed, these and other 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.

3.

Tire pressures.

Hydrostat oil.

5. Tightness of all nuts and bolts.

6.

Electric blade clutch air gap setting.
* Refer to Page 15 for details

Refer to engine service manual provided with your mower for maintenance schedules and
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 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).

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).

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. lbs.

B. OHMS TEST:

1. Disconnect clutch from mower wiring harness which is located
on the right side of the mower frame.

2. Set the multi-meter on RX1 and attach the two leads to the two
wires coming from the electric clutch.

3. The reading you receive should be between 2.4 to 2.9 OHMS.

4. If 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

to raise or lift

lever

plate. At

cut position

rods

use of an

n 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.

wear heavy, thick gloves when holding onto cutter blade, avoid the sharp

mbling blades to hub assemblies, fully tighten blade bolts to a minimum

of 60 ft. Ibs. torque. The use of air impact tools is recommended for installation to insure

s 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

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

or

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
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

with left hand. Move lever to align with the 5th hole from the bottom on the quadrant
this time, connect brake link into hole on lift lever. Move lift lever toward lowest
and remove belt from the top of center deck hub assembly.

from deck while supporting deck assembly with a suitable brace, or by the
assistant to hold the deck while rods are removed. Slide deck from under chassis.

3. Reverse procedure to re-install deck assembly.

CUTTER BLADE REMOVAL:

1 . Carefully place deck assembly i

"Caution"

edge of the blade.

2. When reasse

bolt tightness.

BELT TENSION:

1 . The engine to mower deck drive belt on the Model 5421 i

periodically inspected due to the nature of the job they perform.

quality. If adjustment is required, tighten lock nut on adjustment rod until belt free play
movement between pulleys is approximately 1/4 of an inch.

Page 16

CARE AND MAINTENANCE - MODEL 5421

Adjustment of the drive system is limited to the actual function of the hydrostatic

The idler pulley 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

eve desired

pulley travel of approximately 1 3/4" when the brake handle is released. Tighten nuts

The twisted idler belt (P/N 1 860) should be aligned in the center of the pulley. To adjust

gnment, 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

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

ermine 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

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

eep 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

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,

ottom 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

d. 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

set following this

DRIVE SYSTEM ADJUSTMENTS:

transmissions as outlined below.

1.

between the idler plate and the brake shaft. Turn the rod as required to achi

firmly against the ball joint rod ends. See Figure 1 .

2.

the ali

procedure, if necessary. See Figure 2.

3.

4.

5.

6.

"off" and "on" positions several times to det

results. Repeat procedure, if necessary. See Figure 3.

should be used when releasing parking brake as mower may tend to cr

is obtained on each hydrostat. Re-tighten lock nuts and tension bolts on spring blocks.

check that the forward lever stops on the b

the lever hits the stop block before resistance is felt in the hydrostat. See Figure 4.

Balance of travel spee

DAMAGE TO THE UNIT. If upper control levers are slightly off­adjustment, they can be realigned by bending them slightly.

Refer to the diagrams on the following pages for the location of adjustment points.

Page 18

FORWARD LEVER STOP ADJUSTMENT

Page 19

CARE AND MAINTENANCE - MODEL 5421

(1) each front wheel caster, front wheel, and deck hub for

The use of compressed air pressure greasing methods is

not recommended as damage to seals and bearings could

Using a hand pressure grease gun, lubricate each front

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

CHASSIS AND MOWER DECK:

LOCATIONS:

SERVICE INTERVALS:

RECOMMENDED GREASE:

CAUTION:

LUBRICATION

Number of grease zerks used: (7)

front wheels

Every 50 hours of operation

Name brand wheel bearing or multi-purpose grease

occur.

wheel to allow even

noted completely around each caster axle.

ENGINE OIL CHANGES:
OIL RECOMMENDATIONS:

"Refer to separate owners manual furnished by the
engine manufacturer."

SERVICE INTERVALS:

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 soaps 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.

Page 21

TROUBLESHOOTING

MOWER CUT QUALITY:

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 CAUSES REMEDY

Poor cut quality Ground speed Reduce mowing speed

Poor cut quality Loose belts Adjust per operators manual

Poor cut quality Engine RPM too low Increase engine RPM to maximum

Poor cut quality Dull or bent blades Sharpen or replace as required

Poor cut quality Unlevel mower deck Adjust per operators manual

Poor cut quality

Grass build-up under

Clean out underside of mower deck

mower deck

Poor cut quality Improper blades

Replace with original equipment
blades which are designed for the
Model 5421

Poor cut quality Uneven tire pressures

Check and adjust as required per
operators manual

Page 22

TROUBLESHOOTING

DRIVE SYSTEM:

SITUATION CAUSES REMEDY

Page 23

Mower pulls to one
side or the other

Loss of drive power
on one side or the
other

Loss of power on both
wheels after being
operated for a length
of time

Poor driving
performance

Oil leaks

Drive adjustment

T-Box belts slipping

Belt from engine to

T-Box is slipping

Operation of mower

Loose or missing

hose clamps

Adjust per operators manual
Consult your dealer for repair

Adjust per operators manual
Consult your dealer for repair

Adjust per operators manual
Consult your dealer for repair

Review operators section

of owners manual

Tighten or replace as required

TROUBLESHOOTING

ELECTRICAL SYSTEM:

SITUATION CAUSES REMEDY

Starter will not
turn engine over

Starter will not
turn engine over

Battery discharge

Battery discharge

Battery discharge

Circuit breaker engaged

Push button to reset Consult

your dealer for repair

Dead battery Charge battery

Poor connections on

Tighten or replace as required
battery Battery water low
Wrong battery installed
in mower

Engine electrical system
not functioning correctly

Engine being operated
at too low an RPM

Have electrical system checked by

your dealer

Increase engine RPM Contact your

dealer for information

Electric clutch will
not engage mower
deck blades

Low battery condition
Poor connections on
clutch switch Broken

Repair or replace as required

Consult your dealer for repair

wiring

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

Page 25

Page 26

Page 25

Page 26

Page 27

Page 28

Page 29

Page 30

Page 31

1108

Front Tire

3093

5/1 6"

-

1 8 UNC X 1 " HH Bolt GR5

1512

Rear Tire

3160

5/16" Flat Washer

1685

L-Rod

3163

1/2" Int Tooth Lock Washer

1763

Tie Down w/lnsulator

3188

#10 Ext Tooth Lock

4" A

-

Pulley

1/4"

-

20HexNutw/Nylok

2128

Slee

ve

3217

1/4" SAE Flat Washer

2995

Commercial Decal

3227

5/16"

-

18X2"HHBoltGR5

3008

1/4" ID X 3/4" OD Flat Wa

sher

3249

5/8" Int Tooth Lock Washer

3012

3/8"

-

16UNCHexNut

3257

7/16" Int Tooth Lock Washer

1/4" Helical Lock Washer

5/16"

-

18X1" Soc Head Bolt

3061

5/16"

-

18 UNC 1 3/4" Soc Set Screw

3298

Washer .51 5 X. 874 X. 031

3072

1

/8" X 1 3/4" Hair Pin Cotter

3318

3/8"

-

16X 2 1/4" HH BoltGRS

ZTR 5421 PARTS LIST

1109
1384
1385

1668

1687
1701
1751

1826
1849
1850
1851

1860
1863
1938

2475
2533
2648

3002
3005
3006
3007

3009

3014
3019
3020
3023
3033
3052
3057

3066
3068

3074
3087
3088
3091

Inner Tube - Front Wheel 3100 7/1 6" HD Flat Washer
Tank Mount Bracket (Short) 3106 1/4"X1" Spiral Pin
Tank Mount Bracket (Long) 3130 1/2" Contact Belleville Spring

Drive Pulley 3161 5/1 6"-24 UNF LH Thread

Idler Pulley
Wheel/Deck Hub Bearing
Transaxle Idler Pulley

Caster Bushing

Seat Spacer

Drive Pulley

V-Belt

Caster Tube

Anchor Bracket

Control Rod

Brake Rod

Deck Hub Key

5/16"-18X21/2"HHBoltGR8
5/16"-18UNCHexNut
5/16"-18X1 1/4" HH Bolt GR5

1/4"-20 UNC Hex Nut

5/1 6"- 18 UNC X 1 3/4" HH Bolt GR5

1/4"-20 UNC X 3/4" HH Bolt GR5
5/16" Helical Lock Washer
5/16" Std Flat Washer

1/2" SAE Flat Washer
3/32" X 1 " Cotter Pin
3/8" Std Flat Washer

3/1 6" Std Flat Washer

1/8"X1" Cotter Pin

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

3178 3/8"-16 X 2 1/2" HH Bolt GR5
3182
3187

3193
3195
3203

Flip Lock Bushing
#10-32 Hex Nut

Washer .43 X 1 .38 X .25
Face Nut 1/2"-27
3/8" ID Flat Washer (Narrow)

3204
3205

3206
3208

3220
3224
3225

3231
3235
3237
3247

3256

3266
3267
3268

5/16"-18HexNutw/Nylok
3/8"-16HexNutw/Nylok
#10-24 Hex Nut w/Nylok

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

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

Snap Ring

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

3269
3272
3273

3297

3300
3310

3319
3321
3322
3325

5/16" Int Tooth LW
8-18X3/8" Phillips Pan Hd

1/2"-13Thin Profile Nylok

Foam Pad
5/16"-18Thin Profile Nylok

Idler Shock Mount
5/16"-18X 8 HH BoltGRS
5/16"-18 X 5 1/2" HH Bolt GR8
3/8"-16 X 3/12" HH Bolt GR8

Page 32

ZTR 5421 PARTS LIST

4594

Wire Cover 14"

5649

CCW Fan

-

Machined

5085

Brake Band

6168

Trash Guard

5525

Brake Link Left

6293

Deflector

Mount Bracket

5564

Filter Head

8244

Clutch Kit

5625

Gearbox

8394

3/8" Black Hose 28.5

4584 Start Cable 5643 Input Gear - GB
4585 Battery Ground Cable 5644 Bearing - Gearbox
4587 Wire Cover 61 " 5645 Bearing Spacer - GB
4589 Covered Key 5648 CW Fan-Machined

4598 Circuit Breaker 5650 Hydro
4645 Wire Cover 30" 5651 Hydro
4733 Seat Bottom 6065 Serpentine Idler Spring

4761 Seat Switch Assembly 6075 Engaging Idler Bracket Spacer
4783 Upper Wire Loom 6100 Outer Shaft Key
4784 Lower Wiring Loom 6101 Center shaft Key
4979 Hinge 6109 Serpentine Blade Drive Belt
5070 Key 3/16" SqX 7/8" 6111 Deck Drive Belt

5170 Spring 6236 Mower Blade 42" Standard
5189 Bushing 6260 Blade Washer

5242 Plug w/Hole 6263 Hub Spacer - .459
5249 5/8" Bearing w/Snap 6264 Deck Hub - Machined
5257 Brake Drum (Keyed) 6272 V-Pulley
5283 Link 6282 Tapped Shaft Weldment Long
5522 Brake Link Right 6283 Tapped Shaft Weldment Short

5530 Control Pivot Shaft 6297 Deflector Pin
5531 Adjustable Collar 6366 Mower Deck Weldment

5537 Control Arm Bracket 6370 Mower Deck Assembly
5540 Neutral Adjust Collar 6392 Blow-By Baffle 42"
5554 Spacer 1/2" OD X 1/4" 6744 Spring
5558 Hose Fitting 7015 "L" Rod - 7"
5559 Hose Fitting 7594 Thrust Bearing
5560 Elbow - Male 7647 Wheel & Tire Assembly
5561 Adapter - Male (For 3/8" ID Hose) 7648 Caster Axle RH
5562 Adapter - Male (For 5/8" ID Hose) 7649 Caster Axle LH
5563 Tee - Cast Iron 8167 Caster Wheel Bearing

5565 Oil Filter 8384 Upper Body
5585 Tab 8386 Lower Body

5595 Hose 5/8" X 14" 8389 Frame Assembly
5602 Hose Guard Spring 8390 Front Rim - Black

5624 Tank Cap 8393 3/8" Black Hose 3.75

5632 3/8" Hose - 5" 8395 Wire Kit
5633 5/8" Hose - 2" 8429 Oil Valve/Hose Assembly
5635 Reservoir Assembly 8452 Battery Cover
5636 Brass Ferrule 8455 Serpentine Idler w/Stud
5641 G-Box Mount Spacer 8457 Deflector w/Decal

Page 34

ZTR 5421 PARTS LIST

8576

Rear Rim

9624

Lift Cam Drilled RH

8852

Fuel Line 26.5

9655

Lift Shaft Weldment

9067

Control Rod

9157

Left Swivel Plate

9164

Brake Plate

9174

Brake Rod

9196

Plate

9325

Seat Frame Weldment

9335

Pivot Shaft

9339

Rear Wheel & Tire

9350

Brake Shaft Weldment

9374

Brace

9623

Lift Cam Drilled RH

8688
8772

8854
9031
9049

9082
9098
9110
9142
9156

9158
9159

9165
9171

9172

9191

9212
9268

9280
9312

9329
9330
9332

9334

9336

9342
9344
9346
9347

9372

9377
9618

Mower Blade Hi-Lift 9634 Lift Frame Weldment
Belt Set (1859) 9646 Lift Plate

Fuel Line 6"
Spacer
Lift Bushing Bracket

Seat Frame Pivot Rod

L-Rod9/16"X153/16"

Tank Cover

Lift Rod - Rear
Right Swivel Plate

Control Lever w/Grip Left
Control Lever w/Grip Right

Brake Plate
Spacer 1 .75

Spacer 1 .50

Connecting Link

Spring (Belt Tensioner)
Spacer 1. 25 OD X 1.1 4

Engine Plate
Bumper Weldment

Tie Bar Weldment
Tie Bar Weldment
Spring Anchor

Pulley Mount Plate

Pulley Shaft

Idler/Tube Weldment

Angle Weldment

Engine Plate Weldment
Idler Spring Plate

Body Brace

Brake Lever
Lift Handle Weldment

Page 35

Page 36

NOTES

NOTES

Page 37

Page 38

NOTES

DIXON INDUSTRIES, INC
A BLOUNT COMPANY
AIRPORT INDUSTRIAL PARK

PO BOX 1569
COFFEYVILLE KS 67337 O945

316 251 2OOO

FAX [phone]