Dixon ZTR421, ZTR422, ZTR423 User manual

OPERATOR'S MANUAL FOR ZTR-421, 422, 423 MOWER

ONE-YEAR LIMITED WARRANTY
This lawn mower is warranted for one( 1) year from date of delivery against all defects in materials and workmanship. Lawn
mowers used for commercial service are warranted for 30 days from date of delivery. (Lawn mowers other than those used only
at residence of owner are considered as commercial service.)
Each new mower is warranted against manufacturing defects in material and workmanship under normal use and service. Our
obligation, under this warranty, shall be limited to the replacement to the original retail purchaser of any part or parts, which,
within the warranty period, shall be shown to be defective due to faulty workmanship or materials at the factory. All parts
claimed defective must be returned to the factory for inspection, repair, or replacement with transportation charges prepaid.
This warranty does not apply to damage in transit or damage caused by misuse, negligence or accident, to alterations or
repairs done outside the factory or authorized service stations, nor does it obligate us to assume any transportation charges in
connection with the replacement of parts claimed to be defective.
Our warranty does not apply to the blades, adapters, chains or belts on our mowers due to the very nature of the function-they
perform and to the elements they are exposed to.
The warranty specifically excludes engines, tires, and batteries which are warranted separately by their respective manu -
facturers. All claims for def ective engines or engine parts must be made in accordance with the engine manufacturer's
warranty.
We reserve the right to make changes in design and changes or improvements on our product without imposing any
obligation upon ourselves to install the same on products heretofore manufactured.
This warranty is null and void if any parts other than original manufacturer's parts are used. There is no other express
warranty.
IMPLIED WARRANTIES, including those of merchantability and fitness for a particular purp ose, are limited to one(1) year
from purchase and, to the extent permitted by law, any and all implied warranties are excluded.

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
BEFORE MOWING:
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.
2. Wear appropriate, safe clothing when mowing —close-
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 satisfac torily.
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.
8. Always disengage blades before taking the mower

across walks or objects that project above the surface.
9. When the mower is not in use, turn the engine off; never
leave the engine running unattended. Your Dixon mower is
equipped with a weight-sensitive switch that kills the engine
when operator leaves the seat while blades are engaged.
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.
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.
15. Never lift lawn mower by the body; lift only by the frame.
ALWAYS SET PARKING BRAKE AND DISENGAGE BLADE OPERATION BEFORE DISMOUNTING
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.
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.
3. Move throttle control to "Choke" position.
4. To start models with electric starting, simply insert ignition
key and turn to the far right position. When the engine
starts, release the ignition key and it will 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-

ing rope as soon as engine starts. To stop engine turn key
to "OFF" position.
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:
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.
BRAKING:
To brake mower, move both levers in direction opposite of
travel, release levers to neutral, set parking brake. When
stopping on incline, it may be necessary to hold slight
pressure on levers in direction opposite of slope, until
parking brake is set.
ALWAYS SET PARKING.BRAKE BEFORE DISMOUNTING.
INITIAL OPERATION:
It is recommended that first operation of mower be done at
a slow setting of throttle speed and disengagement of
mower blades until operator is thoroughly familiar with the
unit.
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.

ALWAYS DISENGAGE BLADE OPERATION BEFORE
DISMOUNTING.
9. Parking Brake:
Parking brake is on right hand side of floor area and is
engaged by pushing full forward with foot. To disengage,
pull lever back toward operator by hand. In emergency
situations, brake may be used in conjunction with the
natural braking of the transaxle by applying pressure with
foot. Always set parking brake before dismounting. Be
sure that parking brake is disengaged before moving.
MAINTENANCE
PRE-STARTING INSTRUCTIONS
1. Fill fuel tank with a good grade of regular gasoline. Do not
mix oil with gasoline.
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.
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.
CAUTION:
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.
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.
MOWER DRIVE BELT
Belt tension for the mower drive belt is adjusted by turning the
turnbuckle to provide more forward movement of the engaging
idler.
REPLACE BELTS WHEN ADJUSTMENT CAN NO LONGER
BE MADE SATISFACTORILY OR IF BELTS BECOME
WORN.

BODY REMOVAL
A. ZTR-421 Body Removal
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.
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.
B. ZTR-422 Body Removal
1. Disconnect throttle cable from engine.
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.
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.

CHAIN ADJUSTMENT
To adjust the drive chains, the body must be removed and shims
added behind the transaxle. Loosen 4 bolts which hold the
transaxle to the frame. Insert shims (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.
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.
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.
TRANSAXLE
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.
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.
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 eng aging 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. Name
1000 Frame Weldment (Electric)
1015 Caster Assembly
1020 Caster Axle
1022 Caster Wheel & Tire
1029L Lift Lever & Quadrant Left
1039 Lower Lift Link
1040 Lift Tie Rod
1043 Battery Strap
1100 Frame Weldment (Manual)
1500 Lower Control Lever
1501R Upper Control Lever Right
1501L Upper Control Lever Left
1502 Control Rod Assembly
1504 Wheel Hub & Sprocket
1507 Wheel Bearings
1509 Wheel& Tire
1528 Bellcrank
1535 Chain
1536 Connecting Link
1538 V-Pulley
1539 Drive V-Belt
1540 Key
1541 Shim
Part No. Name
1542 V-Pulley
1543 Lift Knob
1552 Belt Keeper
1560 Battery Splash Guard
1564 Brake Arm 75 Model
1567 Brake Mount 75 Model
1574 Brake Pivot 75 Model
1579 Short Brake Rod 75 Model
1580 Long Brake Rod 75 Model
1581 Brake Pedal Arm 75 Model
1584 Brake Pedal 75 Model
3025
1
/4 x 1 Spiral Pin
3026
1
/4 x 1 1/
2
Spiral Pin
3029 Front Grommet
3030 Rear Grommet
3054 3/16 x 1 Roll Pin
3070
1
/4 x 1
1
/4 Spiral Pin
3501 Nylon Bushing
3502 Hand Grip
3504 Double Ball Joint
4002 Deluxe Seat 36", ZTR-421
4003 Headlight
4004 Switch
Part No. Name
4005 Throttle Cable
4006-1Battery Solenoid Cable
4006-2Battery Ground Cable
4006-3Solenoid-Alternator Cable
4006-4Swith-Headlight Cables, ZTR-421
4006-5Front Loom Assy. Prior to 75
4006-6Rear Loom Assy. Prior to 75
4006-7Rear Loom Assy., ZTR-422
4007 Battery
4008 Solenoid
4009 Wire Clip
4010 Control Decal
4011 Name Decal
4014 Standard Seat 18"
4025 Switch Decal
4027 Pan Loom ZTR-421, ZTR-422
4028 Frame Wire Loom, ZTR-422
4029 Switch Wire Loom, ZTR-422
4030 Seat Switch Wire Loom, ZTR-421
4031 Frame Wire Loom, ZTR-421
4032 Pan Wire Loom, ZTR-423
4033 Frame Wire Loom. ZTR-423
4034 Switch Wire Loom, ZTR-423

Part No. Name
4035 Switchground Wire, ZTR-423
4036 Micro Switch
4037 Front Wire Loom, ZTR-421
4038 Pan By-Pass Plug
4050 Body-White
4051 Body -Blue
5000 Transaxle
5003L Support -Left
5003R Support -Right
5004R Support Assembly Right
5004L Support Assembly Left
5005 Discup
5006 Spacer
5007 Center Frame
5009L Cradle -Left
5009R Cradle -Right
5010R Cradle Assembly Right
501OL Cradle Assembly Left
5011 Support Shaft
5012 Cradle Shaft
5013 Frame Shaft
5014 Torque Rod
5015 24 T Sprocket
5016 Cone
Part No. Name
5018 9 T Sprocket -Narrow
5019 Chain
5021 9 T Sprocket -Wide
5022 Thumb Screw
5023-1Pivot Bolt
5024 Cradle Spring
5025 Frame Assembly
5028 Bearing
5028-ABearing -Notched
5035 Transaxle Pulley
5036 Pivot Spring
5044 Torque Rod Stiffner Kit
5050 Positive Neutral Kit
6025 Mower Deck Assembly
6050 Mower Deck Weldment
6052 Stabilizer Arm
6055 Mower Bearing
6058 V-Pulley
6059 Flat Idler Pulley
6060 Serpentine Idler Bracket
6063 Bronze Bushing
6065 Tension Spring
6070 Engaging Idler Bracket
6075 Spacer
Part No. Name
6077 Bearing Spacer
6078 Pulley Spacer
6086 Connecting Link
6087 Engaging Rod
6088 Turnbuckle
6089 Engaging Handle
6092 Blade
6093 Outer Hub Assembly
6094 Hub
6095 Center Shaft Assembly
6097 Outer Shaft Assembly
6100 Key
6101 Key
6107 Pin
6108 Center Hub Assembly
6109 V-Belt
6110 V-ldler Pulley
6111 V-Belt
6112 Engaging Spring
6113 Blade Washer
6119 Decal
6127 Deflector Assembly
6130 Engaging & Switch Cam 75

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. _______________________________________
2. _______________________________________
3. _______________________________________
Engine tuned this date:
1. _______________________________________
2. _______________________________________
4. _______________________________
5. _____________________________
6. _____________________________
3. _______________________________
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