Dixon ZTR 560 Operator's Manual
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Dixon ZTR 560 Operator's Manual

Dixon ZTR 560 Operator's Manual

Dixon zero turn riding mower operators manual
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  • Page 2: Important - Read Carefully

    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.

  • Page 3: Table Of Contents

    1. SAFETY ...Pages 2. WARRANTY POLICY...Page 3. SPECIFICATIONS...Page 4. SET UP AND SERVICE... Pages 6 - 1 2 5. OPERATION INSTRUCTIONS...Pages 1 3 - 1 4 6. CARE AND MAINTENANCE ... Pages 15-22 7. TROUBLESHOOTING ...Pages 23-25 8. PARTS ILLUSTRATIONS...Pages 26-32 9.

  • Page 4: Safety

    RIDING LAWNMOWERS, IF IMPROPERLY OPERATED, CAN CAUSE SERIOUS INJURY The following examples are the most common causes of injury to the The operator or bystander inserts a hand or foot into the discharge chute 1. BLADE CONTACT: or under the mower deck and into the path of the cutting blade. Never run the mower blades when there are people nearby.
  • Page 5 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.

  • Page 6: Safety Reminders

    SAFETY REMINDERS: Never lift lawnmower by the body, lift only by the frame. Never carry passengers. Use care when pulling loads or using heavy equipment. Use ONLY approved drawbar hitch points. Limit loads to those you can safely control. Do not turn sharply. Use care when backing. Watch out for traffic when crossing or near roadways.

  • Page 7: Warranty Policy

    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.

  • Page 8: Specifications

    CHASSIS: 11 GA - rectangular tube. Two piece - made of rotational molded polyethylene. Front body contains access BODY: panels for battery service and engine to mower deck belt removal. Rear body tilts up to allow service on the entire drive system. Economically designed for operator comfort by use of high density closed cell SEAT: foam, contoured back rest and arm rests.

  • Page 9: Set Up And Service

    SET UP AND SERVICE Seat Assembly Instructions Upper Control Lever Installation Mower Deck Installation Deck Leveling Final Preparation Page 6...
  • Page 10 SEAT ASSEMBLY INSTRUCTIONS Place seat back against frame of seat bottom. Align top & bottom holes in frame with the t-nuts in seat back. Insert (4) 1/4-20 Phillips machine screws to attach frame to seat back. DO NOT TIGHTEN SECURELY. Place (1) armrest bracket against seat back, aligning mounting holes in bracket and seat back.
  • Page 11 SEAT ASSEMBLY INSTRUCTIONS: 12. Install all-thread hex head bolts into seat straps. Place (1) 5/16-18 x 3" bolt through hole located 1- 5/8" from end of strap. Place (1) 5/16-18 x 4" bolt through hole located 2-7/8" from opposite end of strap.

  • Page 12: Upper Control Lever Installation

    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.

  • Page 13: Mower Deck Installation

    MOWER DECK INSTALLATION NOTE: Brake link (P/N 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 DISCARD cotter pin and washer after engine to mower drive belt has been installed.

  • Page 14: Mower Deck Leveling Procedure

    MOWER DECK LEVELING PROCEDURE LEVELING PRINCIPALS: 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.

  • Page 15: 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: Remove battery from chassis. Fill each cell with electrolyte (acid) to ring at bottom of fill cap. Allow battery to sit for (10) minutes, re-check acid level and top off any cells that are low.

  • Page 16: Operation Instructions

    OPERATION INSTRUCTIONS The safe and successful operation of the Model 560 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.
  • Page 17 OPERATION INSTRUCTIONS: 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.

  • Page 18: Maintenance Schedule

    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.
  • Page 19 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 maintainance procedures to extend the life of the clutch as they wear over time.

  • Page 20: Deck Removal

    CARE AND MAINTENANCE - MODEL 560 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 to raise or lift the front of the mower unless proper safety equipment is available to support the mower.
  • Page 21 CARE AND MAINTENANCE - MODEL 560 DRIVE SYSTEM ADJUSTMENTS: Adjustment of the drive system is limited to the actual function of the hydrostatic transmissions as outlined below. Tighten the (2) J-bolts on the T-box mounting plate until each belt has 1/8th to 1/4th of an inch free play or movement at a mid-point between the pulleys on the hydrostats and T-box.
  • Page 22 ADJUSTMENT POINTS FOR T-BOX BELT TENSION Page 18...

  • Page 23: Forward Lever Stop Adjustment

    FORWARD LEVER STOP ADJUSTMENT Page 20...

  • Page 24: Recommended Grease

    CARE AND MAINTENANCE - MODEL 560 LUBRICATION: CHASSIS AND MOWER DECK: Number of grease zerks used: (7) LOCATIONS: SERVICE INTERVALS: RECOMMENDED GREASE: CAUTION: The use of compressed air pressure greasing methods is ENGINE OIL CHANGES: OIL RECOMMENDATIONS: SERVICE INTERVALS: PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS. (1) each front wheel caster, front wheel, and deck hub for front wheels Every 50 hours of operation...

  • Page 25: Cleaning The Mower

    CARE AND MAINTENANCE - MODEL 560 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.

  • Page 26: Troubleshooting

    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...

  • Page 27: Drive System

    DRIVE SYSTEM: SITUATION CAUSES Drive adjustment Mower pulls to one side or the other T-Box belts slipping Loss of drive power on one side or the other Loss of power on both Belt from engine to wheels after being T-Box is slipping operated for a length of time Operation of mower...

  • Page 28: Electrical System

    ELECTRICAL SYSTEM: SITUATION CAUSES Starter will not Circuit breaker engaged turn engine over Starter will not Dead battery turn engine over Poor connections on Battery discharge battery Battery water low Wrong battery installed in mower Battery discharge Engine electrical system not functioning correctly Engine being operated Battery discharge...
  • Page 36 3072 1/8" X 1 3/4" Hair Pin Cotter 3074 5/16"-24UNFHexJamNut 3087 5/1 6"- 18 UNC X 3/4" HH Bolt GR5 3088 1/4"-20X1"HHBoltGR5 ZTR 560 PARTS LIST 3093 5/16"-18 UNC X 1" HH Bolt GR5 3105 1/4" x 1 1/4" Spirol Pin 3130 1/2" Contact Belleville Spring 3140 1/4"...
  • Page 37 ZTR 560 PARTS LIST 3297 1/2"-13Thin Profile Nylok 3298 Washer .51 5 X. 874 X. 031 3300 Foam Pad 3310 5/16"-18Thin Profile Nylok 3318 3/8"-16X2 1/4"HHBoltGR8 3319 Idler Shock Mount 3321 5/16"-18X8"HHBoltGR8 3322 5/16"-18X51/2"HHBGR8 3325 3/8"-16X31/2"HHBGR8 3326 3/8"-16X4"HHBGR8 3331 M6XP1 X8MMHHBGR8.8...
  • Page 38 ZTR 560 PARTS LIST 3955 Clutch Spacer 4124 Solenoid w/Hardware 4197 Ignition Switch 4198 Blade Drive Clutch Switch 4199 Light Switch 4217 Battery 4242 Deck Switch 4256 Utility Box 4274 Choke Cable 4276 Headlight Assembly 4384 Relay 4453 Access Cover Assembly...
  • Page 39 ZTR 560 PARTS LIST 8387 Wiring Kit 8404 Clutch Kit 8429 Oil Valve/Hose Assembly 8432 Axle Housing Assembly 8433 Hydro Mount Housing 8434 Splined Reduction Gear 8435 Final Drive Gear 8436 Axle Assembly 8437 Ball Bearing 8438 Brake Shaft 8439 E-Ring 8440 Ball 3/8"...
  • Page 40 NOTES Page 37...
  • Page 41 NOTES Page 38...
  • Page 42 DIXON INDUSTRIES, INC A BLOUNT COMPANY AIRPORT INDUSTRIAL PARK PO BOX 1569 COFFEYVILLE KS 67337 O945 316 251 2OOO FAX 316 251 4117...

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