Dixon 501 User Manual

INDEX

1. SAFETY Pages 1 - 3

2. WARRANTY POLICY Page 4

3. SPECIFICATIONS Page 5

4. SET UP AND SERVICE Pages 6 - 11

5. OPERATION INSTRUCTIONS Pages 12- 13

6. CARE AND MAINTENANCE Pages 14 -21

7. TROUBLESHOOTING Pages 22 -24

8. PARTS ILLUSTRATIONS Pages 25 - 28

9. PARTS LIST Pages 29 - 31

10. ELECTRICAL SCHEMATIC Page 32

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's manual applies to all Dixon ZTR Model
501 Mowers. Your Dixon dealer will gladly provide a check-out ride, and answer
any questions.

See your dealer for warranty service, parts and repairs.

DIXON INDUSTRIES, INC.

Box 494

Coffeyville, Kansas 67337-0494

Page 1

SAFETY

RIDING LAWNMOWERS, IF IMPROPERLY-OPERATED. CAN CAUSE SERIOUS INJURY.

The following 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 the mower blades when there are people nearby.
Always turn the engine off when cleaning or working around the mower deck.

2. RUN-OVER: This situation occurs when a bystander is run-over or backed over by the
mower. The most frequently cited examples are with small children who wander
into, or are allowed to play, in an area where the mower is being operated.
Never run the mower blades when there are people nearby, especially children.
Young children should be indoors and watched by an adult.
Always look behind you before backing up.

3- TIP-OVER: This occurs when the mower tips over, usually sideways or to the rear.

This situation is due to operation of the mower on steep inclines or near a drop
off.
Mow across the slope to slightly uphill.
Mow slopes when the grass is dry and watch for bumps, holes and other
obstacles.
Test the slope with the blades off. A good rule of thumb is "Don't mow on • a
slope you can't back up".

Stay clear of drop-offs, especially if they are on the down side of a slope.

4. THROWN OBJECTS: The fast spinning mower deck blade can strike stones or other
objects which can be hurled into the path of a bystander. To prevent this from
happening, never remove the safety discharge chute from the mower deck, or
operate the mower when other people are around.

5. FIRES: Most accidents of this type occur during re-fueling of the mower or placing
the mower in a storage situation. The exhaust system and related engine
components operate at very high temperatures which can ignite any fuel spilled
on or near them. Always allow the mower to cool before re-fueling or placing in
storage.

6. OPERATION BY CHILDREN: This mower is not a toy or recreational vehicle.

Never allow children to operate the mower in any manner or to ride as a
passenger.

NOTE: The six examples are the most frequently cited injury causing situations.

Please review all the safety precautions outlined on the following pages
prior to operation of the mower. Our aim is to enhance the safe and
satisfactory use of this product.

SAFETY Page 2

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 satisfactorily.

4. Keep hands and feet away from the blade at all times.

5. Keep persons clear of the discharge chute. Do not operate mower unless deflector
is in place.

6. When mowing hills or slopes, use extreme caution. Reduce speed, do not make
sudden starts, stops or turns.

7. Always disengage blades before taking the mower across walks or objects that
project above the surface.

8. Stay alert for holes, rocks and roots in the terrain, and other hazards. Keep away
from drop-offs.

9. 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.

"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 or servicing your mower, turn off the engine and let it cool. Be
sure all moving parts are stopped. Never run the 501 with the body open.

11. Never run the engine indoors; the fumes are dangerous. ,:

12. Before backing your Dixon Mower; stop, turn around and look.

13. Handle gasoline with care - it is highly flammable.

A. Use approved gasoline container.
B. Never remove the fuel cap of, or add gasoline to, a running or hot engine,

or an engine that has not been allowed to cool after running. Never fill
the tank indoors and always clean up spilled gasoline.

C. Never store the mower, with gasoline in the tank, inside the building where

fumes may reach an open flame or spark. Allow the engine to cool before

storing in any enclosure.

14. Never lift lawnmower by the body; lift only by the frame.

15. Never carry passengers.

SAFETY REMINDERS: (continued)

Page 3

16. Use care when pulling loads or using heavy equipment.

A. Use only approved drawbar hitch points.

B. Limit loads to those you can safely control.

C. Do not turn sharply. Use care when backing.

17. Watch out for traffic when crossing or near roadways.

18. Keep the mower in good operating condition, and keep safety devices in place and
working.

19. Keep all nuts, bolts and screws tight to be sure the mower is in safe working
condition.

20. To reduce fire hazard, keep the engine free of grass, leaves or excessive grease,

21. The mower should be stopped and inspected for damage after striking a foreign object
or if it starts vibrating, and any damage should be repaired before restarting and
operating the mower.

22. When mowing, proceed as follows:

A. Mow only in daylight or in good artificial light.

B. Shut the engine off when removing the grass catcher or unclogging chute.
C. Check the blade mounting bolts for proper tightness at frequent intervals.
D. Never operate the machine when using medication or under the influence of

alcohol or drugs.

WARRANTY POLICY Page 4

Warranty Policy:

Each new Model 501 is warranted against manufacturing defects in material and
workmanship under normal use and service for a period of (1) year or (400)
hours from date of purchase and is extended to the original retail purchaser
of the mower only.

Obligation:

Under this warranty policy Dixon Industries, Inc. shall be limited to the
replacement to the original 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.

What is NOT covered by Dixon Industries, Inc.:

1. TRANSPORTATION CHARGES: Any charges by the dealer or other parties for
transportation of the mower to or from the dealers place of business, also
known as pick up and delivery.

2. ENGINES: The warranty policy and procedures for any engine used on our
mowers is the responsibility and obligation of the individual engine
manufacturer. As such, Dixon Industries, Inc. assumes no responsibility for
either the policies or procedures of said manufacturers.

3. BELTS AND BLADES: Our warranty does not apply to the blades or belts used
on our mowers due to the very nature of the function they perform and to h

the elements they are exposed to.

4. ROUTINE MAINTENANCE: Adjustments or any type of oil or grease used on the
mower.

5. TIRES: Warranty extended by tire manufacturer.

6. PEERLESS GEAR BOX: Warranted for a period of (90) days from date of

purchase of Tecumseh Products Company.

7. NEGLIGENCE: Any failure caused by negligence, improper use or abuse on part
of owner or operator.

Who is authorized to perform warranty service?

Any authorized Dixon ZTR dealer can perform repairs under warranty on our
mowers. If warranty repairs" are needed, please contact the selling dealer
first. If, due to circumstances beyond your control, you are unable to
obtain repairs by the selling dealer, contact the customer service
department of Dixon Industries, Inc. for assistance.

Product updates or improvements:

We reserve the right to make changes in design or improvements on our
products without imposing any obligation upon ourselves to install the same
on products heretofore manufactured.

SPECIFICATIONS

Page 5

Chassis: 11 GA - rectangular tube.

Body: Two piece - made of DR acrylic reinforced with fiberglass, color fast, scratch

and impact resistant. Front body contains access panels for battery service and
engine to mower deck belt removal. Rear body tilts up to allow service on the
entire drive system.

Seat: Ergonomically designed for operator comfort by use of high density closed cell

foam, contoured back rest and arm rests. Seat is adjustable fore and
aft.

Mower Deck: 12 GA stamped steel construction, (3) blades, 50" cut width, cut height 1"

to 4" via 7 position lift handle. Self cleaning design smoothly curved front,
aides discharge of grass.

Blade Drive: Warner electric clutch.

Drive System: {2} Sundstrand BDU - 10 L hydrostatic transmissions driven by a

permanently lubricated peerless gear box.

Engine: 18 HP Briggs and Stratton twin cylinder 1C with cast iron sleeves and

ducted air flow.

Starting System: Electric by key switch operation with safety interlocks on

parking brake and blade drive clutch.

Tires: Front 11 x 4.10 x 5 smooth tread. Rear 20 x 10 x 8 turf savers.

Capacities: Fuel - 4.8 gallons total (dual tanks) with fuel gauges.

Hydrostat oil tank - 3 quart with inline 10 micron filter.
Hydrostat oil recommendation - name brand SAE (10-W-30) motor oil.

Dimensions: Width - 60"

Height - 45"
Length - 72"

Weight - 624 lbs.

NOTE: Additional information provided in service instruction under the

individual component.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE........................

Page 6

SET UP AND SERVICE

1. Seat assembly instructions.

2. Upper control lever installation.

3. Mower deck installation.

4. Deck leveling procedure.

5. Final preparation.

Page 7

SEAT ASSEMBLY INSTRUCTIONS

1. Assemble seat as shown in picture. Do not fully tighten the bolts which secure
left and right arm rest brackets to seat bottom until seat back and tool box are
installed. This will aid alignment of all parts.

2. Place seat assembly on rear body cover, connect seat safety switch.

3. Insert the (2) rear studs of the seat slide into the rear holes of the body

cover. Firmly hold seat assembly against body cover with one hand while rear
body is raised to fully open position. Continue to hold seat against body to

prevent damage to seat safety switch wiring.

4. Install (1) flat washer and (1) nylok nut on (1) of the rear studs extending
through body cover and seat frame, tighten a few threads to hold seat assembly in
place.

5. Position seat on front holes and install all remaining washers and nylok nuts.
Tighten all nuts fully.

Page 8

UPPER CONTROL LEVER INSTALLATION

1. Raise rear body cover to fully open position.

2. Insert left upper control lever on swivel plate.

3. Install fiber washer and jam nut.

;

4. Proper tightness or tension on jam nut is achieved when swing out movement of upper
control levers requires some pressure. Levers should not fall to the side or be
sloppy in movement.

5. Repeat procedure on right side.

MOWER DECK INSTALLATION

Page 9

1. To remove front body from chassis, disconnect headlights and remove acorn nut
in middle of body.

2. Install rear hanger rods on lift frame, as shown in the diagram. Slide lift

plate on hanger rods, small holes in lift plate will face rear of mower,
install bushings and start nylok nuts on each hanger rod until approximately
1/4 inch of threads are exposed.

3. Position mower deck under chassis.

4. Place lift lever in 3rd hole from highest cut, position #5 on quadrant.

5. Using (1) of the deck support rods, insert the rod at the corner of the lift

frame and the front of the mower chassis in the groove provided on the lift
frame. Pry backwards on the lift frame enough to connect the brake link into
the hole on the tab of the lift lever. This will allow for belt installation
in step #7.

6. Raise mower deck at the rear and slide (1) of the deck support rods through
the mower deck lift plate and the tabs of the mower deck. "Note" A length of
2x4 board turned on end and placed under the mower deck for support will
make this task easier if the installation is being done by one person, due to
the weight of the mower deck.

7. Raise front of mower deck and slide front support rod through lift frame and

tabs on mower deck. Install hair pin clips on front and rear support rods.

8. Move lift lever to lowest cut position, install engine to mower deck drive
belt on top center pulley. Check belt routing after installation to make
certain that belt is centered in groove of electric clutch pulley.

9. Move lift lever toward high cut position and remove brake link from hole
on lift lever.

10. Install deflector chute on mower deck by using nuts and bolts
provided. Never operate mower without deflector chute in place.

Page 10

Leveling Principals:

MOWER DECK LEVELING PROCEDURE

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.

Leveling the Deck:

A. Place the mower on a smooth level surface, check tire pressures to insure the

mower has a correct stance. Inflate tires as required:

Front - (40 - 46 lbs. maximum)
Rear - (20 - 24 lbs. maximum)

B. Remove the discharge chute from the mower deck. Rotate or turn each outer blade

tip to align with the edge of the deck or side to side.

C. Measure from the surface up to the bottom of the blade tip on the discharge side

of the mower deck. Retain this measurement. Move to the opposite side and check
that measurement is the same. If adjustment is required, turn the nut on the
bottom of the front threaded adjuster up or down until both side to side
measurements are equal. Retain measurement.

D. Rotate or turn both outer blades to align with the deck in a front to rear

NOTE:

This will place the mower deck in a base measurement position. Additional
adjustment may be required to achieve desired cut for the type of grass or
conditions being mowed.

manner. Move to the left rear threaded adjuster, "left rear is designated from
operator position on the mower". Turn adjuster nut up or down until rear of
mower deck is positioned level to l/8th of an inch higher than the side to side
measurement. At this time, the mower deck will hang or be suspended on (3)
points. Move the right rear adjuster and take out the slack which will be
present by turning adjuster lock nut up. Confirm the measurement used on the
left rear of the deck. Re-install discharge chute.

FINAL PREPARATION

1. Remove battery from chassis.

2. Fill each cell with electrolyte (acid) to ring at bottom of fill cap.

3. Allow battery to sit for (10) minutes, re-check acid level and top off any
cells that are low.

4. Trickle charge battery using a charger of less than (6) amps until all cells
are gassing freely. Hydrometer readings may be taken, if desired.

5. Install permanent battery caps and wash any accumulated acid from battery
before re-installation on chassis.

6. Observe proper battery polarity when re-connecting leads on chassis. Always
connect positive lead first.

Engine Service:

1. Final preparation of engine should be completed using engine service manual
provided with mower.

Initial Start and Hydrostat Transmission Check:

1. Final hydrostat checks have been performed at the factory, however, it is
necessary to check that the pressure relief bypass on each hydrostatic
transmission is completely released before attempting to drive mower.

2. Each hydrostat has a bypass relief pin located at the bottom front of the

unit. A stop plate is provided to allow the mower to be rolled around
without complete servicing of the unit. To accomplish this, the stop
plate must be positioned to depress the bypass relief pin. If the stop
plate is depressing the pin, loosen the lock nut on the stop plate and
rotate the stop plate outward which will allow the pin to pop out to the
fully extended position. Tighten lock nut on stop plate at this point.

Page 12

OPERATION INSTRUCTIONS

The safe and successful operation of the Model (501) will depend upon the operator
having the correct knowledge of all controls used on the mower and making good
judgments about the terrain to be mowed. Never allow anyone to operate the mower
without complete knowledge of all controls and their functions.

Sound judgment by the owner will prevent accidents.

Controls and their functions. All controls described from operators position.

PARKING BRAKE:

The parking brake used on the Model (501) is designed to hold the mower from moving
and is not intended for use in stopping the mower while it is in motion. An
additional safety feature of the parking brake is that the engine cannot be started
unless the brake is applied.

THE HYDROSTATIC DRIVE SYSTEM:

Allows the mower to turn on its own axis (zero radius). Each lever controls one
side of the mower. The pressure required to operate the mower is very light and a
minimum of 1/2 hour should be spent simply driving the mower in a non-mowing
application to gain the confidence necessary to mow like a pro.

LEVER MOVEMENTS:

No shifting or clutching required.

TO GO FORWARD:

Release parking brake. From neutral position, gently puch both drive levers
forward; to increase speed, move levers farther forward.

TO GO BACKWARD:

From neutral position, gently pull both drive levers toward you.

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.

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.

CHOKE CONTROL LEVER:

Used to start a cold engine. (Engine has not been operated for a length of time)
Located on control panel to operators right.

Page 13

OPERATION INSTRUCTIONS (continued)

THROTTLE CONTROL LEVER:

Control's engine speed. (Engine should be operated at full throttle when used in a
mowing application, this will insure adequate cooling of the engine as well as
maintaining mower deck blade speed) Located on control panel on operators right.

MQKER DECK CUT HEIGHT LIFT LEVER:

Controls the cutting height of the mower deck. Seven positions of adjustment in
which the very top, or highest notch, is used for transporting the mower in a non­mowing situation. Located in front of operator on the right side of mower.

BLADE DRIVE:

To engage the mower deck cutter blades, lift switch up lightly and push
forward. To disengage blades, pull switch backward. Switch is clearly
marked "on and off".

LIGHT SWITCH:

The headlights are activated by pushing the switch forward. Failure to turn off
the lights, once the engine is stopped, will result in rapid discharge of the
battery.

FUSE BLOCK:

Protection of the electrical system is by (1) 10 AMP fuse. To remove the fuse for
inspection, push down and turn cap to the left. If fuse burns quickly, please
consult your dealer for inspection and repair. Never attempt to by-pass the fuse by
any method.

Page 14

CARE AND MAINTENANCE - MODEL 501

This portion of the Model 501 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 your mower.

NOTE:

The disassembly and repair of the Sundstrand BDU 10 L hydrostatic transmissions is
best left to a qualified Sundstrand repair and service facility. These repair
centers are equipped with the necessary tools and service information to accurately
perform all service required. Due to the precision nature of these transmissions,
field repairs cannot be recommended.

MAINTENANCE SCHEDULE:

To insure a long and trouble free service life on all the components used on the
Model (501) a regular and thorough maintenance schedule should be followed. As with
any type of precision made equipment, a certain amount of initial bedding in or
seating of the components will take place. The following items should be checked
after the first (10) hours of operation and on a weekly basis, or each (40) hours of
use:

1. Drive system chains, belts and controls.

2. Mower deck belts

3. Tire pressures.

4. Hydrostat oil.

5. Tightness of all nuts and bolts.

Refer to engine service manual provided with your mower for maintenance schedules
and procedures to be used on the engine.

Page 15

necessary equipment, entrust this task to your dealer.

installation to insure bolt tightness.

CARE AND MAINTENANCE - MODEL 501

MOWER DECK SERVICE: 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 not
attempt to raise or lift the front of the mower unless proper safety
equipment is available to support the mower. If you do not have the

DECK REMOVAL:

1. Remove front belt access cover from body. Stand in front of the mower,
grasp lift quadrant lever, with left hand. Move lever to align with the
(5th) hole from the bottom on the quadrant plate. At this time, connect
brake link into hole on lift lever. Move lift lever toward lowest cut
position and remove belt from the top of center deck hub assembly.

2. Remove the hair pin cotters from the ends of the deck support rods. Slide
deck support rods from deck while supporting deck assembly with a suitable
brace, or by the use of an assistant to hold the deck while rods are
removed. Slide deck from under chassis.

3. Reverse procedure to re-install deck assembly.

CUTTER BLADE REMOVAL:

1. Carefully place deck assembly in a manner which will allow access to the blade
bolts. Hold blade from turning while bolt is removed from the center of each hub
assembly. "Caution" wear heavy, thick gloves when holding onto cutter blade,
avoid the sharp edge of the blade.

2. When re-assembling blades to hub assemblies, fully tighten blade bolts to

a minimum of (35 ft. lbs.) torque. The use of air impact tools is recommended for

BELT TENSION:

.1. The engine to mower deck drive belt on the Model (501) is automatically held

in proper tension by springs which push the deck assembly forward, and does
not require any additional adjustment to be made. Both the belt and the
idler system should be periodically inspected due to the nature of the job
they perform.

2. Serpentine deck belt tension is maintained by a manual adjustment rod which

is located on the top of the mower deck assembly. Proper belt tension is
critical to insure cut quality. If adjustment is required, tighten lock nut
on adjustment rod until belt free play or movement between pulleys is
approximately 1/4 of an inch.

Page 16

CARE AND MAINTENANCE - MODEL 501

DRIVE SYSTEM ADJUSTMENTS: Hydrostat Chains - Belts - Cable - Controls

Refer to the diagrams on the following pages for the location of adjustment points.

Step 1. Loosen the front and rear mounting bolts of the hydrostat, turn the rear

adjustment bolt downward, which will tension the final drive chain to the
rear wheel. Chain is correctly tensioned when at a point mid-way between
the sprockets chain free play or movement is approximately l/16th of an inch
up and down. Re-tighten mounting bolts.

Step 2. Loosen the (2) bolts which secure the front chain adjustment, refer to

diagram, turn the front adjustment bolt downward using a 5/16th alien
wrench. Correct tension is as in step #1. Re-tighten bolts.

Step 3. Repeat above procedures on opposite hydrostat.

Step 4. Tighten the (2) J-bolts on the T-box mounting plate until each belt has l/8th

to l/4th of an inch free play or movement at a mid-point between the pulleys
on the hydrostats and T-box.

Step 5. Position parking brake lever in the off or disengaged position. This will allow

the belt idler used on the engine to T-box to swing fully and apply tension to
the belt. At this time, check that the cable which pulls the idler to a neutral
position has approximately 1-1/2 to 2 inches of free play. If adjustment is
required, loosen the lock nuts on the cable block and turn cable sleeve in or
out to achieve desired measurement. Re-tighten lock nuts. "NOTE" Cable must
have the above dimension with parking brake released or drive belt may slip,
causing a loss of power.

Step 6. Neutral adjustment must be checked at this time which will require the engine to

be started and the parking brake released. Swing upper control levers outward
and into neutral slots, start engine, use caution when releasing parking brake
as mower may tend to creep or move prior to re-adjustment of neutral settings
on each hydrostat. If adjustment is required, loosen lock nuts at each end of
the control rods and back off the tension bolt on each spring block. Turn
control rod in or out until neutral is obtained on each hydrostat. Re-tighten
lock nuts and tension bolts on spring blocks.

Step 7. Stop engine, move levers to drive position. Lightly push each upper control lever

forward until a resistance is felt on the lever. At this time, check that the
forward lever stops are hitting against stop block. "NOTE: Do not allow levers
to travel to completely forward without hitting stop blocks as damage to
hydrostats could result. If adjustment is required, loosen lock nut on lever
stop and turn bolt in to allow lever to hit the stop before resistance is felt
in the hydrostat.

Step 8. Start engine. Drive mower forward and observe driving condition. If mower tends

to pull to either side, re-adjust lever stop on fast side to slow that hydrostat
down and even out the ground speed. Do not speed up slow side as over stroking
of the hydrostat could result in damage to the unit. If upper control levers are
slightly off-set after this adjustment, they can be realigned by bending them
into alignment.

(1) HYDROSTAT MOUNTING BOLTS

Page 17

(2) THREADED ADJUSTERS TO TENSION CHAINS

(1) ADJUSTMENT POINTS FOR T-BOX BELT TENSION

Page 18

(1) Forward lever stop adjustment

Page 19

CARE AND MAINTENANCE - MODEL 501

Page 20

LUBRICATION:

CHASSIS AND MOWER DECK: Number of grease zerks used (3)

LOCATIONS: (1) each front wheel caster

SERVICE INTERVALS: Every (50) hours of operation

RECOMMENDED GREASE: Name brand wheel bearing or multi-purpose grease

CAUTION: The use of compressed air pressure greasing methods
is not recommended as damage to seals and bearings could occur.

Using a hand pressure grease gun, lubricate each front caster to allow even
distribution of grease within the caster, rotate or spin each front wheel caster
after (3) pumps of the grease gun. Repeat process until the appearance of grease is
noted completely around each caster.

DRIVE CHAINS: Primary and final drive
RECOMMENDED LUBRICANT: Name brand aerosol chain spray
SERVICE INTERVALS: As required for operating conditions

Remove excess dirt from chains, lubricate each chain completely by applying the lube
to the inside of each connecting link. Applying lube directly to the top of the chain
will only allow the lube to be thrown off in operation. The chains are of special
construction which use o-rings to seal a factory lubricant inside of the chain.
Additional lubrication will cushion chain to sprocket engagement. Avoid the use of
any lubricants which may damage the o-rings used on this chain.

ENGINE OIL CHANGES: "Refer to separate owners manual furnished by the

OIL RECOMMENDATIONS: engine manufacturer."

SERVICE INTERVALS:

Please dispose of used oils at proper collection centers. Protect your environment.

Page 21

CLEANING THE MOWER:

CARE AND MAINTENANCE - MODEL 501

A clean machine 1s 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. A better approach is the use of mild

household soaps and low water pressure. A stiff brush can be used to loosen excess

grass and dirt build up. Avoid directing water pressure onto the mower deck hub

assemblies, electrical wiring and engine components such as air filter openings. Never

wash or clean the Sundstrand BDO 10 L hydrostatic transmissions, as damage to these

units could result. To remove excess water which accumulates during washing of the

mower either blow off with compressed air, if available, or start the engine, allowing

a long enough operation time to dry thoroughly. It is advisable to engage the mower

deck for a short time to disperse all water from pulleys and belts.

Please help protect the environment by avoiding all chemicals which may damage or

cause harm to plants and animals in your area.

Page 22

TROUBLE SHOOTING

Poor cut quality Improper blades

Replace with original

Poor cut quality

Uneven tire pressures

Check and adjust as

MOWER CUT QUALITY:

There are many variables that can effect the cut quality of any multi blade
mower. Type and condition of grass, ground speed, blade speed, and conditions
are some of the variables that interact creating differences in cut quality
results. In most cases, a smooth, even cut will be achieved without further
adjustment.

The Trouble Shooting 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 REMEDY

Poor cut quality Ground speed Reduce mowing speed

Poor cut quality Loose belts Adjust per operators
manual

Poor cut quality Engine RPM too low Increase engine RPM to

Poor cut quality Dull or bent blades Sharpen or replace as
required

Poor cut quality Unlevel mower deck Adjust per operators
manual

Poor cut quality Grass build-up under Clean out underside of
Mower deck mower deck

equipment blades which are
designed for the Model 501

required per operators manual

TROUBLE SHOOTING Page 23

DRIVE SYSTEM:

Poor driving

performance

Oil leaks

Tighten or replace as

required

Loose or missing

hos

e clamps

SITUATION

CAUSES

REMEDY

Mower pulls to one
side or the other

Loss of drive power
on one side or the
other

Loss of power on both
wheels after being
operated for a length
of time

Drive adjustment

Adjust per operators
manual

Consult your dealer for
repair

T-Box belts slipping

Adjust per operators
manual

Consult your dealer for
repair

Belt from engine to
T-Box is slipping

Adjust per operators
manual

Consult your dealer for
reoair

Operation of
mower

Review operators section
of owners manual

Page 24

TROUBLE SHOOTING

ELECTRICAL SYSTEM:

SITUATION

CAUSE

REMEDY

Blown fuse

Dead battery

Charge batte

ry

Starter will not

turn engine over

Starter will not
turn engine over

Battery discharge

Battery discharge

Inspect and replace fuse

If fuse continues to burn
consult your dealer for
repair

Poor connections on
battery
Battery water low
Wrong battery installed in
mower

Engine electrical system
not functioning correctly

Tighten or replace as
required

Have electrical system
checked by your dealer

Battery discharge

Electric clutch will
not engage mower
deck blades

Engine being operated at
too low an RPM

Low battery condition
Poor connections on
clutch switch
Broken wiring

Increase engine RPM
Consult your dealer for
information

Repair or replace as
required
Consult your dealer for
repair

Head lights do not
operate

Note:

Poor connection, on lights
Broken wiring Bad bulb

Repair or replace as
required

Electrical system failures are generally simple in nature, always check the
obvious first and then move onto the more complicated parts used. Poor battery
service, loose connections, corrosion, frayed or broken wiring, are more likely
than component failure.

Illustration – Mower Deck Assembly 50” (Model 501)

Illustration — Body Assembly (Model 501)

Illustration – Transmission Assembly (Model 501)

Illustration —Chassis Assembly (Model 501)

Page 29

ZTR 501 - PARTS LIST

PART# DESCRIPTION
1657 Spring - Belt Idler
1668 Drive Pulley
1675 Clutch Anchor
1682 L-Rod
1701 Wheel/Deck Hub Bearing
1702 Locking Collar
1712 Battery Strap
1714 T-Box Drive Belt
1715 Rear Wheel & Tire
1732 Pulley - T-Box
1733 Pulley - T-Box Drive
1734 Pulley Hydrostat
1739 Hydrostat Idler Bracket
1742 Bumper
1743 Hydrostat Flat Idler Pulley HO
1744 Hydrostat Drive Belt
1745 Pulley
2128 Sleeve
2414 Spring
2460 Parking Brake Decal
2823 Oil Drain Assembly
3005 5/16"-18 UNC Hex Nut
3006 5/16"-18 x 1 1/4" HH Bolt Gr 5
3007 1/4"-20 UNC Hex Nut
3008 1/4" ID x 3/4" 00 Flat Washer
3009 5/16"-18 UNC x 1 3/4" HH Bolt Gr 5
3014 l/4"-20 UNC x 3/4" HH Bolt Gr 5
3019 5/16" Helical Lock Washer
3020 5/16" Std Flat Washer
3023 1/4" Helical Lock Washer
3029 Front Grommet
3031 5/16"-18 UNC Acorn Nut
3033 1/2" SAE Flat Washer
3035 1/2"-13 UNC Hex Jam Lock Nut
3037 3/8"-24 UNF x I 1/4" HH Bolt Gr 5
3047 3/8"-24 UNF Hex Lock Nut
3048 3/8"-16 UNC x 1 i/2" HH Bolt
3052 3/32" Dia x 1" Cotter P1n
3054 3/16" Dia x 1" Roll P1n
3056 5/16" Fender Washer
3057 3/8" Std Flat Washer
3061 5/16"-18 UNC 1 3/4" Soc Set Screw
3065 3/8" Helical Lock Washer
3066 3/16" Std Flat Washer
3072 1/8" x 1 3/4" Hatr Pin Cotter
3074 5/16"-24 UNF Hex Jam Nut
3081 16-32 UNC Hex Nut
3082 16 Lock Washer
3087 5/16"-18 UNC x 3/4" HH Bolt Sr S
3088 l/4"-20 x 1" HH Bolt Gr 5
3090 l/4"-20 x 1 1/4" HH Bolt Gr 5
3091 l/4"-20 UNF Hex Lug Nut
3093 5/16"-18 UNC x 1" HH Bolt Gr 5
3101 7/16" Helical Lock Washer
3106 1/4" x 1" Spirol P1n
3107 1/4" x 1 1/2" Spiral Pin
3118 Disc Spring
3133 #8-32 x 1 1/2" TR 3 Screw
3134 l/4"-28 x 1/4" Soc Set Screw
3145 #6 Std Flat Washer
3151 16-32 UNC x 1/2" Rd Hd Screw
3161 5/16"-24 UNF LH Thread
3163 1/2" Int Tooth Lock Washer
3169 3/8"-16 x 1" HH Bolt Gr 5
3174 l/2"-13 x 1" HH Bolt

PART# DESCRIPTION
3180 l/4"-2Q Hex Locknut
3182 Flip Lock Bushing
3184 5/l6"-18 x 1 1/4" Pan Hd Phillips Screw
3185 Washer
3186 #12-24 x 3/4" Drill & Tap Screw
3187 #10-32 Hex Nut
3188 #10 Ext Tooth Lock Washer
3193 Washer .43 x 1.38 x .25
3194 Face Nut 5/8"-32
3195 Face Nut l/2"-27
3196 Face Nut 7/16"-28
3198 l/4"-20 Wing Nut w/Nylok
3204 1/4"-20 Hex Nut w/Nylok
3205 5/16"-18 Hex Nut w/Nylok
3206 3/8"-16 Hex Nut w/Nylok
3208 #10-24 Hex Nut w/Nylok
3220 7/16"-20 x 2 3/4" HH Bolt Gr 5
3224 5/8"-18 x 3/4" HH Bolt w/Nylok Gr 5
3225 3/8"-16 x 2 1/4" HH Bolt
3228 5/B"-11 x 6 1/4" Carriage Bolt
3229 Washer
3231 9/16" Std Flatwasher
3233 Battery Hold Down Bolt
3235 #10-24 x 5/8" Phillips Pan Hd Screw
3243 5/16"-18 x 3 1/4" HH Bolt Gr 5
3245 3/8"-16 Thin Profile Nylok Nut
3247 #6-20 x 1/2" Phillips Pan Hd Screw
3248 5/16" ID x 1/8" Thick Washer
3249 5/8" Int Tooth Lock Washer
3256 Snap Ring
3257 7/16" Int Tooth Lock Washer
3258 5/16"-18 x 4 1/2" HH Bolt Gr 8
3259 5/16"-18 x 5" HH Bolt Gr 8
3260 1/4”-20 x 1/2" HH Bolt Gr 5
3262 3/4”-10 Thin Profile Nylok Nut
3263 5/8”--11 Thin Profile Nylok Nut
3264 5/I6" Disc Spring HD
3265 #10-24 x 3/4" Truss Hd Phillips Screw
3266 1/4” Int Tooth Lockwasher (Not Shown)
3267 5/16"-18 x 1 3/8" HH Bolt Gr 5
3268 3/8"-24 x 1 1/4" HH Bolt Gr 8 w/Nylok
3269 5/16"-18 x 1" Soc HB
3270 5/16"-18 x 3" Soc HB
3271 1"-14 Thin Profile Nylok Nut
3300 Foam Pad
3511 Adhesive Bumper Pad
3521 Engaging Cam Mount Bushing
3531 Decal - OPERATING INSTRUCTIONS
3S36 Decal - DANGER
3552 Tank Mount Bracket - Long
3553 Tank Mount Bracket - Short
3554 Fuel Cap/Guage

3558. 2 Gal Tank w/Cap-Gauge
3578 Nylon Bushing
3585 Decal - CUTTING HEIGHT
3589 Spacer (Electic Clutch)
3590 Key 1/4" Sq x 1/2"
3599 Iso Mount Assembly
3600 Rebound Mount
3601 Load Mount
3602 Spacer Tube
3603 Iso Mount Insert
3617 Decal - DIXON
3635 Tee-Fuel Line
3644 Fuel Line 7 1/2"

Page 30

PART# DESCRIPTION
3645 Fuel Line 18"
3646 Fuel Line 20"
3649 Fuel Line Clamp
3653 Floor Pad Left Front
3654 Floor Pad Right Front
3655 Floor Pad Left Rear
3656 Floor Pad Right Rear
3669 Decal - CAUTION
3695 J-Bolt
3700 Model Decal - (501)
3702 Pulley
3705 Velcro Strip - Hook
3706 Velcro Strip - Latch
3710 Handle Grip
3711 Hour Meter
3712 Handle Grip
3713 Foam Tube
3714 End Cap
3715 End Cap
3716 1/4" Hose Clamp
3717 3/8" Hose Clamp
3718 5/8" Hose Clamp
3719 Heat Shield Deflector
3720 "Tie Wrap
3721 Decal - DANGER
3722 Fibre Washer
3723 Decal - RESERVOIR
4013 Wire Tie
4075 10 Amp Fuse
4092 Fuse Holder
4124 Solenoid w/Hardware
4144 Seat Slide w/o Adjuster
4145 Seat Slide w/Adjuster
4146 Nylon Washer
4151 Utility Box Trim
4197 Ignition Switch
4198 Blade Drive Clutch Switch
4199 Light Switch
4201 Switch Key (Used w/4197)
4211 Solenoid Starter Cable
4216 Battery Ground Cable
4217 Battery
4242 Deck Switch
4257 Utility Box
4268 Upper Wiring Loom
4269 Lower Wiring Loom
4274 Choke Cable
4275 Throttle Cable
4276 Headlight Assembly
4284 Relay
4331 Battery Cable
4385 Seat Back
4400 Arm Rest Offset
4401 Arm Rest Bracket Left
4402 Arm Rest Bracket Right
4403 Arm Rest Assembly Left
4404 Arm Rest Assembly Right
4405 Battery Cover w/Velcro
4415 Seat Bottom
4428 Ground Wire (Hour Meter)
4430 Cover - Flex Guard
4446 Cover - Flex Guard
4448 Engine Wire Assembly
4453 Access Cover Assembly
5028 Bearing

ZTR 501 - PARTS LIST

PART# DESCRIPTION
5070 Key 3/16" Sq x 7/8"
5085 Brake Band
5087 Spacer 3/8" x 1/2"
5101 Brake Link
5112 Key-Sq 3/16" x 1 1/2" (Fits 5110)
5170 Spring
5189 Bushing
5500 T-Box
5501 Mount Plate
5502 Mount Shim
5503 T-Box Guide Left
5504 T-Box Guide Right
5507 Brake Plate Bracket Left
5508 Brake Plate Bracket Right
5510 Sprocket 10T
5511 Sprocket 30T
5512 Sprocket 10 T w/Brake Drum
5514 Brake Rod 5/16" x 2 5/8"
5515 Idler Cable
5516 Swivel
5519 Brake Arm Left
5521 Brake Arm Right
5522 Brake Link Right
5525 Brake Link Left
5530 Control Pivot Shaft
5531 Adjustable Collar
5537 Control Arm Bracket
5539 Hydrostat Support Rod
5540 Neutral Adjust Collar
5544 Swivel Bracket Control Lever Left
5545 Swivel Bracket Control Lever Right
5546 Control Rod End Left
5547 Control Rod End Right
5549 Brake Handle
5550 Hydrostat Left
5551 Hydrostat Right
5553 Spacer 1/2" OD x 2 1/2"
5554 Spacer 1/2" OD x 1/4"
5555 Fan Left
5556 Fan Right
5558 Hose Fitting
5559 Hose Fitting
556C Flbow - Male
5561 Adapter - Male (For 3/8" ID Hose)
5562 Adapter - Male (For 5/8" ID Hose)
5563 Tee - Cast Iron
5564 Filter Head
5565 Oil Filter
5566 Hose 3/8" x 7"
5567 Hose 3/8" x 13"
5568 Chain - Primary - Short
5575 Shaft 3/4" x 8 1/4"
5576 Spacer
5577 Drive Chain - Secondary
5579 Electric Clutch HO
5580 Jack Shaft Bracket Left
5581 Jack Shaft Bracket Right
5582 Pivot Shaft Bracket
5583 Hose 5/8" x 19"
5584 Hose 1/4" x 14"
5585 Tab
5591 Reservoir Assembly
5592 Control Lever w/Gr1p Left Hand
5593 Control Lever w/Grip Right Hand
5594 Tube

PART# DESCRIPTION

Page 31

5595 Hose 5/8" x 14"
6011 Mower Deck Bearing
6059 Flat Idler
6100 Outer Shaft Key
6101 Center Shaft Key
6111 Deck Drive Belt
6113 Blade Washer
8504 Seat Slide Spring
8570 Upper Body w/Decals
8571 Lower Body w/Decals
8572 Headlight Bulb
8573 Headlight Bulb Socket
8575 Wheel Hub Assembly
8576 Rear Rim
8577 Rear Tire
8580 Caster Wheel
8581 Caster Tire
8585 Wiring Kit
8602 Hardware Kit (Electric Clutch)
8645 Seat Assembly (501)
8648 Chain Connecting Link
8649 Rotor/Armature Assembly
8650 Clutch Field Assembly
8645 Cap For Reservoir
9002 Frame
9017 Seat Frame
9020 Caster
9022 Caster Axle Bushing
9023 Engine Mount Plate - Fwd
9024 Engine Mount Plate - Rear
9031 Spacer
9035 Lift Frame
9049 Lift Bushing Bracket
9055 Lift Cam Left
9056 Lift Cam Right
9057 Lift Rod
9065 Lift Handle
9066 Lift Shaft
9067 Control Rod
9076 Seat Frame Cable
9082 Seat Frame Pivot Rod
9088 Caster Wheel & Tire
9089 Control Rod Assembly
9098 L-Rod 9/16" x 15 3/16*
9104 Control Panel
9110 Tank Cover
9111 Rear Wheel Hub
9136 Tube
9200 Mower Deck Assembly
9201 Mower Deck Pan
9212 Spring (Belt Tensioner)
9219 Deck Hub
9224 Outer Shaft
9225 Center Shaft
9226 Deck Hub Sub Assembly
9228 Deck Hub Bearing Spacer
9229 Mower Blade
9230 Outer Hub Assembly
9231 Center Hub Assembly
9233 Deck Idler Bracket
9236 Serpentine Blade Drive Belt
9242 Pulley Guard
9245 Deflector
9254 Lift Plate

ZTR 501 - PASTS LIST