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Dixon 560 manual

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Table of contents for the manual

  • Page 1

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  • Page 2

    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. The information in this operator&apo[...]

  • Page 3

    INDEX 1. SAFETY ............................................................... Pages 1 - 3 2. WARRANTY POLICY ........................................... Page 4 3. SPECIFICATIONS ................................................ Page 5 4. SET UP AND SERVICE ........................................ Pages 6 - 12 5. OPERATION INSTRUCTIONS ............[...]

  • Page 4

    SAFETY RIDING LAWNMOWERS, IF IMPROPERLY OPERATED, CAN CAUSE SERIOUS INJURY The f ollowing examples are the most common causes of injury to the operator or bystander... 1. BLADE CONTACT: The operator or bystander inserts a hand or foot into the discharge chute or under the mower deck and into the path of the cutting blade. Never run th e mower blade[...]

  • Page 5

    S AFETY SAFETY REMINDERS: READ CAREFULLY BEFORE OPERATION 1. Wear appropriate, safe clothing when mowing - close fitting jeans or slacks and heavy leather or safety shoes with rough soles. Never operate this mower with bare feet or open sandals. 2. Do not operate on wet or slippery grass. 3. Always mow at the slowest speed that will cut satisfactor[...]

  • Page 6

    SAFETY RE MINDERS: (Continued) 14. Never lift lawnmower by the body, lift only by the frame. 15. Never carry passengers. 16. Use care when pulling loads or using heavy equipment. A. Use ONLY approved drawbar hitch points. B. Limit lo ads to those you can safely control. C. Do not turn sharply. Use care when backing. 17. Watch out for traffic when c[...]

  • Page 7

    DIXON LIMITED WARRANTY POL ICY -- HYDRO - GEAR MODELS 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 f irst. Mowers used for residential homeowner applications [...]

  • Page 8

    SPECIFICATIONS CHASSIS: 11 GA - rectangular tube. BODY: Two piece - made of rotational molded polyethylene. Front body contains access panels for bat tery service and engine to mower deck belt removal. Rear body tilts up to allow service on the entire drive system. SEAT: Economically designed for operator comfort by use of high density closed cell [...]

  • Page 9

    SET UP AND SERVICE 1. Seat Assembly Instr uctions 2. Upper Control Lever Installation 3. Mower Deck Installation 4. Deck Leveling 5. Final Preparation Page 6[...]

  • Page 10

    SE AT ASSEMBLY INSTRUCTIONS 1. Place seat back against frame of seat bottom. Align top & bottom holes in frame with the t - nuts in seat back. I nsert (4) 1/4 - 20 Phillips machine screws to attach frame to seat back. DO NOT TIGHTEN SECURELY. 2. Place (1) armrest bracket against seat back, aligning mounting holes in bracket and seat back. 3. In[...]

  • Page 11

    12. Install all - thr ead 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. Secure each bolt to strap using (1) 1/8" thick washer and (1 ) 5/16 - 18 hex nut w/nylok. See illus[...]

  • Page 12

    UPPER CONTROL LEVER INSTALLATION 1. Raise rear body cover to fully o pen position. 2. Install flat washer on right hand swivel plate weldment. Next install right hand control lever, then second flat washer. 3. Push control lever into the neutral slot and install (2) cup washers, (1) flat washer and jam nut. (See illustration) 4. Tig hten jam nut. P[...]

  • Page 13

    MOWER DECK INSTA LL ATION 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 an d washer. REMOVE AND DISCARD cotter pin and washer after engine to mower dr[...]

  • Page 14

    MOWER DECK LEVELING PROCEDURE LEVELING PRINCIPALS: A. 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. LEVEL[...]

  • Page 15

    FINAL PREPARATI ON 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: 1. Remove battery from chassis. 2. Fill each cell with electr olyte (acid) to ring at bottom of fill cap. 3. Allow battery to sit for[...]

  • Page 16

    OPER ATION 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 comple te knowledge of all controls and their functions. Sound judgement by [...]

  • Page 17

    OPERATION INSTRUCTIONS: (Continued) 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 u[...]

  • Page 18

    CARE AND MAINTENANCE - MODEL 560 This portion of the Model 560 owners manual deals with normal service items which can be performed by the owner. 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 yo[...]

  • 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 a[...]

  • Page 20

    CARE AND MAINTENANCE - MODEL 560 MOWER DECK SERVICE CUTTER BLADE REMOVAL - BELT TENSION: "CAUTION" The removal of the cu tter 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 s[...]

  • 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 be low. 1. 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 hy[...]

  • Page 22

    ADJUSTMENT POINTS FOR T - BOX BELT TENSION Page 18[...]

  • Page 23

    FOR WARD LEVER STOP ADJUSTMENT Page 20[...]

  • Page 24

    CARE AND MAINTENANCE - MODEL 560 LUBRICATION: CHASSIS AND MOWER DECK: Number of grease zerks used: (7) LOCATIONS: (1) each front wheel caster, front wheel, and deck hub for front wheels SERVICE INTERVALS: Every 50 hours of operation RECOMMENDED GREASE: Name brand wheel bearing or multi - purpose grease C AUTION: The use of compressed air pressure g[...]

  • Page 25

    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 m[...]

  • Page 26

    TROUBLESHOOTING MOWER CUT QUALITY: There are many variables that can effect the cut quality of any multi - blade mower. Type and conditions of grass, cut height setting, engine RPM and ground speed are some of the variables that interact creating differences in cut quality. Examination of one or more of the above will ge nerally produce a quality c[...]

  • Page 27

    DRIVE SYSTEM: TROUBLESHOOTING SITUATION CAUSES REMEDY Mower pulls to one side or the other Drive adjustment Adjust per operators manual Consult your dealer for repair Loss of drive power on one sid e or the other T - Box belts slipping Adjust per operators manual Consult your dealer for repair Loss of power on both wheels after being operated for a[...]

  • Page 28

    TROUBLESHOOTING ELECTRICAL SYSTEM: SITUATION C AUSES REMEDY Starter will not turn engine over Circuit breaker engaged Push button to reset Consult your dealer for repair Starter will not turn engine over Dead battery Charge battery Battery discharge Poor connections on battery Battery water low Wro ng battery installed in mower Tighten or replace a[...]

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    ZTR 560 P ARTS LIST 1384 Tank Mount Bracket (Short) 3093 5/16" - 18 UNC X 1" HH Bolt GR5 1385 Tank Mount Bracket (Long) 3105 1/4" x 1 1/4" Spirol Pin 1657 Spring - Belt Idler 3130 1/2" Contact Belleville Spring 1682 L - Rod 3140 1/4" ID Disc Spring 1701 Wheel/Deck Hub Bearing 3160 5/16" Flat Washer 1714 T - Box Dr[...]

  • Page 37

    ZTR 560 PARTS LIST 3297 1/2" - 13Thin Profile Nylok 3600 Rebound Mount 3298 Washer .51 5 X. 874 X. 031 3601 Load Mount 3300 Foam Pad 3602 Spacer Tube 3310 5/16" - 18Thin Profile Nylok 3603 ISO Mount Insert 3318 3/8" - 16X2 1/4"HHBoltGR8 3635 Tee - F uel Line 3319 Idler Shock Mount 3644 Fuel Line 7 1/2" 3321 5/16" - 18X[...]

  • Page 38

    ZTR 560 P ARTS LIST 3955 Clutch Spacer 5554 Spacer 1/2" ODX 1/4" 4124 Solenoid w/Hardware 5558 Hose Fitting 4197 Ignition Switch 5559 Hose Fitting 4198 Blade Driv e Clutch Switch 5560 Elbow - Male 4199 Light Switch 5561 Adapter - Male (For 3/8" ID Hose) 4217 Battery 5562 Adapter - Male (For 5/8" ID Hose) 4242 Deck Switch 5563 Te[...]

  • Page 39

    ZTR 560 PARTS LIST 8387 Wiring Kit 9171 Spacer 1 .75 8404 Clutch Kit 9172 Spacer 1 .50 8429 Oil Valve/Hose Assembly 9174 Brake Rod 8432 Axle Housing Assembly 9175 Spring Anchor 8433 Hydro Mount Housing 9191 Connecting Link 8434 Splined R eduction Gear 9192 Tie Bar 8435 Final Drive Gear 9196 Plate 8436 Axle Assembly 9212 Spring (Belt Tensioner) 8437[...]

  • Page 40

    NOTES Page 37[...]

  • Page 41

    NOTES Page 38[...]

  • Page 42

    DIXON INDUSTRIES, INC A BLOUNT COMPAN Y AIRPORT INDUSTRIAL PARK PO BOX 1569 COFFEYVILLE KS 67337 O945 316 251 2OOO FAX 316 251 4117[...]