Dixon Lawn Mower ZTR421 ZTR422 ZTR423 User Manual

OPERATOR'S MANUAL FOR ZTR-421, 422, 423 MOWER  
 
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  
2. Wear appropriate, safe clothing when mowing — close-  
BEFORE MOWING:  
fitting 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 its low center  
of gravity and weight biased to the rear; however, caution  
should be exercised when mowing hills or slopes with any  
mower.  
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 al-  
lowed 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.  
8. Always disengage blades before taking the mower  
 
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. Vibra-  
tion is usually the warning of trouble.  
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.  
15. Never lift lawn mower by the body; lift only by the frame.  
ALWAYS SET PARKING BRAKE AND DISENGAGE BLADE OPERATION BEFORE DISMOUNTING  
3. Move throttle control to "Choke" position.  
4. To start models with electric starting, simply insert ignition  
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.  
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-  
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.  
 
BRAKING:  
ing rope as soon as engine starts. To stop engine turn key  
to "OFF" position.  
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.  
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:  
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.  
From neutral position push both drive levers slightly for-  
ward; 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.  
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.  
 
CAUTION:  
ALWAYS DISENGAGE BLADE OPERATION BEFORE  
DISMOUNTING.  
9. Parking Brake:  
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.  
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.  
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.  
MAINTENANCE  
PRE-STARTING INSTRUCTIONS  
1. Fill fuel tank with a good grade of regular gasoline. Do not  
mix oil with gasoline.  
MOWER DRIVE BELT  
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 10-30 oil as outlined in the  
engine instruction manual.  
Belt tension for the mower drive belt is adjusted by turning the  
turnbuckle to provide more forward movement of the engaging  
idler.  
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.  
REPLACE BELTS WHEN ADJUSTMENT CAN NO LONGER  
BE MADE SATISFACTORILY OR IF BELTS BECOME  
WORN.  
 
B. ZTR-422 Body Removal  
BODY REMOVAL  
1. Disconnect throttle cable from engine.  
A. ZTR-421 Body Removal  
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.  
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.  
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.  
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.  
 
CHAIN ADJUSTMENT  
TRANSAXLE  
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.  
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.  
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.  
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.  
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.  
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 engaging 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 avail-  
able by-pass (P/N 4038) must be used.  
 
BODY ASSEMBLY  
CHASSIS ASSEMBLY  
 
MOWER DECK ASSEMBLY  
TRANSAXLE ASSEMBLY  
 
PARTS LIST  
Part No.  
4005  
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  
4008  
4009  
4010  
4011  
4014  
4025  
4027  
4028  
4029  
4030  
4031  
4032  
4033  
4034  
Name  
Throttle Cable  
Part No.  
1542  
1543  
1552  
1560  
1564  
1567  
1574  
1579  
1580  
1581  
1584  
3025  
Name  
V-Pulley  
Lift Knob  
Belt Keeper  
Part No.  
Name  
1000  
1015  
1020  
1022  
Frame Weldment (Electric)  
Caster Assembly  
Caster Axle  
Battery Splash Guard  
Brake Arm 75 Model  
Brake Mount 75 Model  
Brake Pivot 75 Model  
Short Brake Rod 75 Model  
Long Brake Rod 75 Model  
Brake Pedal Arm 75 Model  
Brake Pedal 75 Model  
1/4 x 1 Spiral Pin  
Caster Wheel & Tire  
1029L Lift Lever & Quadrant Left  
1039  
1040  
1043  
1100  
1500  
Lower Lift Link  
Lift Tie Rod  
Battery Strap  
Frame Weldment (Manual)  
Battery  
Solenoid  
Wire Clip  
Control Decal  
Name Decal  
Standard Seat 18"  
Switch Decal  
Pan Loom ZTR-421, ZTR-422  
Frame Wire Loom, ZTR-422  
Switch Wire Loom, ZTR-422  
Seat Switch Wire Loom, ZTR-421  
Frame Wire Loom, ZTR-421  
Pan Wire Loom, ZTR-423  
Frame Wire Loom. ZTR-423  
Switch Wire Loom, ZTR-423  
Lower Control Lever  
1501R Upper Control Lever Right  
1501L Upper Control Lever Left  
3026  
1/4 x 1 1/2 Spiral Pin  
Front Grommet  
Rear Grommet  
3/16 x 1 Roll Pin  
1/4 x 1 1/4 Spiral Pin  
Nylon Bushing  
1502  
1504  
1507  
1509  
1528  
1535  
1536  
1538  
1539  
1540  
1541  
Control Rod Assembly  
Wheel Hub & Sprocket  
Wheel Bearings  
Wheel& Tire  
Bellcrank  
Chain  
Connecting Link  
V-Pulley  
3029  
3030  
3054  
3070  
3501  
3502  
3504  
4002  
4003  
4004  
Hand Grip  
Double Ball Joint  
Deluxe Seat 36", ZTR-421  
Headlight  
Drive V-Belt  
Key  
Shim  
Switch  
 
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  
Part No. Name  
Bearing Spacer  
Pulley Spacer  
Connecting Link  
Engaging Rod  
Turnbuckle  
5018  
5019  
5021  
5022  
9 T Sprocket - Narrow  
Chain  
9 T Sprocket - Wide  
Thumb Screw  
Part No.  
4035  
4036  
4037  
4038  
4050  
4051  
5000  
5003L Support - Left  
5003R Support - Right  
5004R Support Assembly Right  
5004L Support Assembly Left  
5005  
5006  
5007  
5009L Cradle - Left  
5009R Cradle - Right  
5010R Cradle Assembly Right  
501OL Cradle Assembly Left  
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  
5023-1 Pivot Bolt  
Engaging Handle  
Blade  
Outer Hub Assembly  
5024  
5025  
5028  
Cradle Spring  
Frame Assembly  
Bearing  
Hub  
5028-A Bearing - Notched  
Center Shaft Assembly  
Outer Shaft Assembly  
Key  
5035  
5036  
5044  
5050  
6025  
6050  
6052  
6055  
6058  
6059  
6060  
6063  
6065  
6070  
6075  
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  
Key  
Pin  
Discup  
Spacer  
Center Frame  
Center Hub Assembly  
V-Belt  
V-ldler Pulley  
V-Belt  
Engaging Spring  
Blade Washer  
Decal  
Deflector Assembly  
Engaging & Switch Cam 75  
Support Shaft  
Cradle Shaft  
Frame Shaft  
Torque Rod  
24 T Sprocket  
Cone  
 
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. _______________________________  
 
® Dixon and ZTR are the trademarks of Dixon Industries Inc. Box 494 Coffeyville, Kansas 67337  
LITHO IN U.S.A.  
FORM NO. 812-476  
 

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