Dixon Lawn Mower 422 424 User Guide

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SERIAL NUMBERS  
The lawn mower has three serial numbers:  
Mower Number — Located on frame at right rear transaxle mount. Transaxle Number — Located on transaxle.  
Engine Number — Located on engine. When referring to serial number on Warranty Registration, etc., use Mower  
Serial Number located on frame.  
deflector which directs downwards all blade -  
SAFETY INSTRUCTIONS  
propelled objects, keep persons clear of the  
BEFORE MOWING  
discharge chute. Do not operate mower unless  
1. Read these safety instructions and  
engine manufacturer's operating and  
maintenance instructions that are  
furnished with the mower.  
2. Discuss proper maintenance with your  
Dixon dealer, to save money and prevent  
injury. Consult your dealer before  
removing any parts.  
3..Don't allow anyone to operate your  
Dixon mower without proper instruction.  
Young children should never be allowed  
to operate any power mower, riding or  
walking.  
4. Before mowing, pick up all debris —  
particulary stones and sharp objects.  
5. Before starting the engine, make sure  
the gas cap is in place.  
deflector is in place.  
7. Use extreme caution 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 en gine when  
operator leaves the seat while blades are  
engaged. Test this important safety feature  
before each time mower is used. 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 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. Vibration is usually the warning of  
trouble.  
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 satjsfactorily.  
5. Keep hands and feet away from the  
blade at afl times.  
15. Never lift lawn mower by the body; lift only by  
the frame.  
16. Never carry passengers.  
6. Although the Dixon mower is equipped  
with a missile  
ALWAYS SET PARKING BRAKE AND DISENGAGE BLADE OPERATION BEFORE DISMOUNTING.  
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TO GO BACKWARD  
From neutral position gently pull both drive  
levers  
IMPORTANT OPERATING  
INSTRUCTIONS  
rearward.  
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.  
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.  
1. SET PARKING BRAKE — Be sure that drive  
levers are free and in the neutral position.  
(When drive levers are released, they should  
return to neutral position.)  
2. "Blade Operation" lever is to be set in the  
"Disengage" position.  
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.  
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.  
NOTE: Some electric start models are also  
equipped with manual start provision.  
To start engine manually turn switch to  
"RUN" and pull the starter rope.  
INITIAL OPERATION  
It is recommended that first operation of mower  
be done at a slow throttle setting with mower  
blades disengaged u ntil operator is thoroughly  
familiar with the unit.  
5. Set engine to desired speed by adjusting  
throttle control. (Suggest set at slow speed  
during initial operation.)  
6. NOTE SAFETY FEATURE: Safety switches  
stop engine when operator leaves seat while  
blades are engaged, and engine cannot be  
started when blades are engaged. OPERATOR  
SHOULD TAKE PRECAUTIONS AND NOT  
RELY ON SAFETY SWITCHES.  
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 gently push both drive  
levers forward; to increase speed move levers  
further forward.  
You may have a tendency to "over  
control" mower at first. Slight movement  
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 in to  
position by releasing button knob.  
• To start mower blades, move lever on floor to  
"engage" position. To stop mower blades,  
move lever to "disengage" position.  
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ALWAYS DISENGAGE BLADE OPERATION  
BEFORE DISMOUNTING.  
terminal. (See also wiring diagram shown on  
Body Assembly illustration.)  
3. Clean top of battery and terminals.  
4. Do not remove battery from mower.  
5. To reactivate, reconnect cables to correct  
terminals and charge battery if needed.  
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.  
BELT ADJUSTMENT  
The best tension for a V-belt drive is the lowest  
tension at which the belts will not slip under  
normal load condition. Check the tension on a  
new belt frequently during first hours of operation  
and every 10-15 hours or monthly thereafter.  
Too much tension shortens belt and bearing life.  
Too little tension causes slippage and loss of  
power. Be sure that belts and pulleys are kept  
free of foreign material. If belt slippage occurs,  
tighten it just enough to prevent slippage.  
MAINTENANCE  
BEFORE PERFORMING ANY MAINTENANCE,  
SHUT OFF ENGINE, ALLOW TO COOL AND  
DISCONNECT SPARK PLUG.  
ENGINE  
For complete engine operating and maintenance  
information, refer to engine operating and maintenance  
instructions furnished by the engine manufacturer and  
supplied with each mower.  
TRANSAXLE DRIVE BELT  
To adjust tension, loosen 4 bolts which hold  
engine to mount and belt keeper in place.  
Loosen tension bolt located at rear of machine.  
Adjust tension bolt until desired tension is  
achieved, tighten 4 bolts holding engine and  
tighten tension bolt lock nut.  
BATTERY  
Procedure for initial activation of battery:  
1. Fill with electrolyte solution to lower ring of battery.  
2. Let stand for 30 minutes.  
3. Charge at 4 amps for 3 hours or 1 amp for 12 hours.  
4. After initial filling, fluid level may be maintained with  
distilled water.  
MOWER DRIVE BELT  
Belt tension for mower drive belt is adjusted by  
loosening nut on mower deck turnbuckle  
assembly and turning turnbuckle to achieve  
desired tension. Retighten nut. Tension should  
be checked with belt in engaged position.  
Procedure for off-season storage:  
1. Charge battery.  
2. Disconnect cables from battery terminals. Identify  
cables so that they may be easily reconnected to -the  
correct  
REPLACE BELTS WHEN ADJUSTMENT  
CAN NO LONGER BE MADE  
SATISFACTORILY OR IF BELTS BECOME  
WORN.  
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BODY REMOVAL  
CHAIN DRIVES  
ADJUSTMENT  
A. ZTR-424 Body Removal  
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 as needed for adjustment  
between transaxle and mount plates. When properly  
adjusted, the slack span at the mid -point of the  
chain should have a total possible movement  
perpendicular to the chain of about 9/16". Tighten  
the 4 bolts which hold the transaxle to the frame.  
Replace chain when rollers become loose, chain  
breaks, or chain fails to operate properly.  
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  
pedal arm by removing  
the two bolts. 7. Remove two acorn nuts on front  
floor and the two sheet  
LUBRICATION  
1. Chains: Proper lubrication is important for  
effective roller chain operation. Use high quality  
lubricating oil (do not use grease or extra heavy  
oil) and apply drops of oil to the chain joints  
every 10-15 hours of operation.  
metal screws in transaxle body mount. Body will  
lift  
clear. To replace body reverse the above  
procedure.  
2. Front Caster Assembly: Each caster assembly  
has a grease fitting located on the under side of  
the bearing. For best results, use any good  
multi-purpose grease every 10-15 hours of  
operation.  
3. All other Bearings: All other bearings on your  
mower are sealed and require no lubrication.  
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.  
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 20-24 Ibs. Lug nuts should be checked  
periodically.  
OMIT STEP (3) AND FOLLOW ZTR-424 BODY  
REMOVAL INSTRUCTIONS FROM STEP (4) ON.  
REMEMBER TO REINSTALL SWITCH GROUND  
WIRE ON LEFT REAR TRANSAXLE BODY  
MOUNT SCREW.  
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TRANSAXLE  
ELECTRICAL SYSTEMS  
For adjustment or repair confer with authorized  
Dixon dealer service department. Adjustment or  
repair by other than authorized dealer voids  
warranty.  
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.  
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 ½ “ 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 lower engine 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 lift linkage to mower deck on the inside of the  
attaching lugs as shown on drawing with pins and  
clips. (4 places)  
7. Attach stabilizer arms to pivot point on the inside of  
attaching bracket with pins and clips.  
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.  
10. After installing pin clips, rotate pins so that open end of clip  
is down.  
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TRANSAXLE ASSEMBLY 5000-102  
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TRANSAXLE ASSEMBLY 5000  
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PARTS LIST FOR 42"  
MODELS  
Part No.  
Name  
Part No.  
Name  
3105 HD 1/4' x 1 1/4" Spirol Pin (not shown)  
3106 HD 1/4'x 1" Spirol Pin (not shown)  
1629 Bumper Weldment  
1635 Double Engine Pulley  
1636 Bellcrank Kit  
Part No.  
1000C Frame Weldment  
1015 Caster Weldment  
1020 Caster Axle  
Name  
3107 HD 1 4" x 11  
/ /2" Spirol Pin (not shown)  
3118 Disc Spring  
3502 Hand Grip  
1638 Lower Control Lever Assembly  
1640  
1641  
1643  
Tension Plate 11 h.p.  
Pan Switch Spacer  
Brake Pedal  
1022  
Caster Wheel & Tire  
3504 Double Ball Joint  
1022A Caster Wheel Bearing  
1039 Lower Lift Link  
3507 Floor Pad - Long (not shown)  
3508 Floor Pad - Short (not shown)  
3511 Adhesive Bumper  
4003 Headlight Assembly, ZTR-424  
4005B Throttle Cable  
1645 Seat Bracket, ZTR-422  
1040  
Lift Tie Rod Weldment  
1646  
1647  
2221  
Weight Brace  
Control Pin  
Transaxle Shim 16 ga.  
1501R Upper Control Lever R  
1501L Upper Control Lever L  
1502  
Control Rod Assembly  
4006-1 Battery - Solenoid Cable  
4006-2 Solenoid Starter Cable  
4006-3 9" Ground Wire  
4006-4 Headlight Switch Wire, ZTR-424  
4006-7 Rear Wire Loom, ZTR-422  
4007 12 Volt Battery  
4008 Solenoid  
4009 Wire Clip (not shown)  
4010 Control Decal, ZTR-424  
4011-1 Name Decal, DIXON  
4014 Seat - ZTR-422  
4014A Seat Assembly, ZTR-422 (includes 4054)  
4022 Ground Terminal ZTR-421/424  
4024A Headlight Ground Wire, ZTR-421/424  
4025 Switch Decal, ZTR-424  
4028 Frame Wire Loom, ZTR-422  
4029-1 Switch Loom, ZTR-422  
4030-1 Seat Switch Wire Loom, ZTR-424 (not shown)  
2222 Transaxle Shim 22 ga.  
2436 Switch Decal, ZTR-422  
2813 Seat Switch, ZTR-422  
1503 Wheel Hub Assembly  
1504  
1506  
1507-1 Wheel/Hub Bearing  
1509 Rear Wheel & Tire  
1513  
1535  
1536  
1539  
1540  
1543  
Wheel Hub  
Hub Flange  
3
3016  
3017  
3018  
3022  
3025  
3026  
/8" 24UNF x 1" Lug Bolt  
1/2" 13UNC Tension Nut  
1/2" 13UNC x 3" HH Tension Bolt  
1
Tension Plate 8 h.p.  
Drive Chain  
Chain Connecting Link  
Transaxle Drive Belt  
Engine Shaft Key  
Lift Knob  
/
4" Int.-Ext. Lockwasher (not shown)  
1/4" x 1" Spirol Pin (not shown)  
1
/
4" x 1 1  
/2" Spirol Pin (not shown)  
3029 Front Grommet  
5
3031  
3032  
3038  
3039  
3047  
3054  
/
/
/
16" 18UNC Acorn Nut (not shown)  
2" Helical Lockwasher (not shown)  
4" 16UNF Hex Jam Locknut (not shown)  
1
3
1544 Bellcrank Assembly  
1552 Belt Keeper Weldment  
1560-1 Battery Splash Guard  
3/8" 24UNF Hex Lug Nut (not shown)  
3/8" 24UNF Hex Locknut  
3
1564  
1574  
1579  
1580  
1581  
1591  
1606  
1607  
1624  
Brake Arm Weldment  
Brake Pivot Weldment  
Short Brake Rod  
Long Brake Rod  
Brake Pedal Arm Weldment  
Brake Pedal Pin  
Brake Mount Weldment  
Brake Stop  
Oil Drain Assembly  
/
16" x 1" Roll Pin (not shown)  
3057 3/8" Std. Flat Washer (not shown)  
3059 Spring Wire Clip (not shown)  
3070  
3072  
3099  
3100  
3101  
1/4" x 1 1/4" Spirol Pin (not shown)  
4031  
Frame Wire Loom, ZTR-424  
4037 Switch Loom, ZTR-424  
4046 Seat Switch Assembly, ZTR-424  
4049 Decal, ZTR-422  
Hair Pin Cotter (not shown)  
7
/
/
/
16" 20UNF x 3/4" HH Bolt  
16" HD Flat Washer  
16" Lockwasher  
7
7
4050 Body, ZTR-424  
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Part No.  
4051  
Name  
Body, ZTR-422  
Part No.  
5014 Torque Rod  
5015 24 T Sprocket  
5016 Moulded Cone (each)  
5018 9 T Sprocket - Narrow  
5019 Transaxle Chain  
Name  
Part No.  
6058 V-Pulley  
6059 Flat Idler Pulley  
Name  
4054 Seat Switch Assembly, ZTR-422  
4058 Arm Rest Bracket R, ZTR-424  
4059 Arm Rest Bracket L, ZTR-424  
4060 Arm Rest  
4061 Pan Switch  
4062 Switch Boot  
4063 Pan Loom  
4065 Decal, ZTR-424  
4067 Ignition Switch  
4067A Switch Key (for 4067)  
4069 Seat Bottom, ZTR-424  
4070 Seat Back, ZTR-424  
4071 Seat Assembly, ZTR-424 -  
4072 Wiring Kit, ZTR-422  
4074 Wiring Kit, ZTR-424  
5000 Transaxle, ZTR-422  
5000-102 Transaxle, ZTR-424  
5001 Rear Tube Assembly  
5002 Front Tube  
5003R Support R, ZTR-422  
5003L Support L, ZTR-422  
5004R Support Assembly R ZTR-422  
5004L Support Assembly L, ZTR-422  
5005 Discup  
6060 Serpentine Idler Weldment  
5
6063  
/ /8" ID Bronze Bushing  
8" OD x 3  
6065 Serpentine Idler Spring  
6070 Engaging Idler Weldment  
6075 Engaging Idler Spacer  
5021 9 T Sprocket - Wide  
5022 Thumbscrew  
5023-1 Pivot Bolt  
5024 Cradle Spring  
6077-1 Bearing Spacer (use w/6094-1)  
6078 Pulley Spacer  
5025 Cone Frame Assembly, ZTR-422  
5028 Transaxle Bearing  
6087 Engaging Rod  
6089 Engaging Handle  
6092 Mower Blade  
5028A Notched Bearing, ZTR-422  
5035 Transaxle V-Pulley, ZTR-422  
5036 Pivot Spring  
5044 Torque Rod Stiffener L  
5045 Torque Rod Stiffener R  
5046 Positive Neutral Rod  
5047 Positive Neutral Spring  
5050 Positive Neutral Kit  
6093-1 Outer Hub Assembly  
6094-1 Deck Hub Casting  
6095-1 Center Shaft  
\
6097-1 Outer Shaft  
.,  
6100 Outer Shaft Key  
6101 Center Shaft Key  
6107 Deck Pin  
5055 Torque Rod Stiffener Kit  
5059 Double Bearing, ZTR-424  
6108-1 Center Hub Assembly  
6109 V-Belt  
6110 V-ldler Pulley  
6111 Deck Drive V-Belt  
6113 Blade Washer  
6119 Caution Decal  
5061R HD Support Assembly R, ZTR-424  
5061L HD Support Assembly L, ZTR-424  
5065 HD Cone Frame Assembly, ZTR-424  
5066 HD Cone Frame Shaft, ZTR-424  
5068 HD Pulley Spacer, ZTR-424  
5069 HD Transaxle Pulley, ZTR-424  
5070 Transaxle Key, ZTR-424  
5073R HD Support R, ZTR-424  
5073L HD Support L, ZTR-424  
5077 HD Cone Frame, ZTR-424  
6030 Mower Deck Assembly  
6040 Mower Deck Weldment  
5006 Support Spacer  
5007 Cone Frame, ZTR-422  
5009R Cradle R  
6123 Engaging Idler Stud Bushing  
6127 Deflector Weldment  
5009L Cradle L  
.
6134 Engaging Spring  
5010R Cradle Assembly R  
5010L Cradle Assembly L  
5011 Support Shaft  
5012 Cradle Shaft  
5013 Cone Frame Shaft, ZTR-422  
5
6135  
/16" Turnbuckle  
6136 Engaging Cam Weldment  
6148A Connecting Arm Assembly  
6151 Mower Deck Bearing  
6052 .Stabilizer Arm  
8005 Fiberglass Repair Kit (limited shelf life)  
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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. ______________________________  
4. ____________________________  
5. ______________________________  
6. ______________________________  
"
•*  
"
Engine tuned this date:  
1. ____________________________  
2. ______________________________  
3. ______________________________  
4. ______________________________  
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Form No. 4089-1279 Litho in U.S.A.  
® DIXON and ZTR are registered trademarks of Dixon Industries, Inc.  
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