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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