Dixon 5501 User Manual

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 5501 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. A
BLOUNT COMPANY AIRPORT
INDUSTRIAL PARK PO BOX 1569
COFFEYVILLE KS 67337 0945
316251 2000 FAX [phone]

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............................. Pages 13- 14

6. CARE AND MAINTENANCE ................................ Pages 15-22

7. TROUBLESHOOTING ......................................... Pages 23-25

8. PARTS ILLUSTRATIONS..................................... Pages 26-32

9. PARTS LIST ......................................................... Pages 33-36

The operator or bystander inserts a hand or foot into the discharge chute

r

run the mower blades when there are people nearby. Always turn the

over or backed over by the

s 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

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

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

offs, especially if they are

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

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

led on or near them. Always allow the mower to

This mower is not a toy or a recreational vehicle. Never allow children

SAFETY

RIDING LAWNMOWERS, IF IMPROPERLY OPERATED,

CAN CAUSE SERIOUS INJURY

The following examples are the most common causes of injury to the

1 . BLADE CONTACT:

2. RUN-OVER:

3. TIP-OVER:

4. THROWN OBJECTS:

operator or bystander...

or under the mower deck and into the path of the cutting blade. Neve

engine off when cleaning or working around the mower deck.

This situation occurs when a bystander is run­mower. The most frequently cited example

an adult. Always look behind you before backing up.

a drop-off. Mow across the slope to slightly uphill. Mow slopes

slope you can't back up". Stay clear of drop­on the down side of a slope.

deck, or operate the mower when other people are around.

5. FIRES:

6. OPERATION BY
CHILDREN:

Most accidents of this type occur during re-

can ignite any fuel spil
cool before re-fueling or placing in storage.

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.

Page 1

SAFETY

indoors and always clean up spilled gasoline.

SAFETY REMINDERS: READ CAREFULLY BEFORE OPERATION

1.

2.

3.

4.

5.

6.

7.

8.

9.

Note:

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.

Do not operate on wet or slippery grass.

Always mow at the slowest speed that will cut satisfactorily.

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

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

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

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

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

drop-offs.

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.

This important safety feature must be tested prior to each mowing. 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.

11.

12.

13.

Page 2

Before adjusting or servicing your mower, turn off the engine and let it cool. Be sure all moving
parts are stopped. Never run the 5501 with the body open.

Never run the engine indoors; the fumes are dangerous.

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

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

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.

B. Limit loads to those you can safely control.

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.

SAFETY REMINDERS:

(Continued)

14.

15.

16.

17.

18.

19.

20.

21.

22.

Never lift lawnmower by the body, lift only by the frame.

Never carry passengers.

Use care when pulling loads or using heavy equipment.

A. Use ONLY approved drawbar hitch points.

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

Watch out for traffic when crossing or near roadways.

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

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

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

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.

When mowing, proceed as follows:

D. Never operate the machine when using medication or under the influence of alcohol

or drugs.

Page 3

DIXON LIMITED WARRANTY POLICY - 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 first. Mowers used for residential homeowner applications (used only at owner's primary place of residence) are
warranted for two (2) years from date of purchase or 400 hours of use, whichever occurs first. DIXON ZTR MOWERS
ARE WARRANTED AGAINST DEFECTS IN MATERIALS AND WORKMANSHIP AND PROVIDES FOR REPLACEMENT
OR REPAIR OF PARTS INCLUDING LABOR COSTS. THIS WARRANTY IS SUBJECT TO THE FOLLOWING
CONDITIONS AND LIMITATIONS:

1. Warranty applies only to original retail purchaser of new and unused mowers and accessories.

2. All Dixon warranty must be accomplished by authorized Dixon dealers and in accordance with Dixon warranty policy and
allowances. All warranty claims must be approved by Dixon Industries, Inc.

3. Battery warranty: Limited to 90 days from date of purchase.

4. Accessories Warranty (Grass Catchers, Snow Blades, Tine Rakes, Covers, etc.): Limited to 90 days from date of purchase.

5. Warranty does not apply to damage in transit or incidents of misuse, negligence, accidents, or alteration. The use of parts
or components other than those supplied by Dixon Industries, Inc. VOIDS ALL WARRANTY.

6. The following items are not covered by this warranty policy:
(a) Pick up and delivery charges for transportation of mower to and from an Authorized Dixon Dealer's place of business.

(b) Routine maintenance or adjustments.
(c) Belts / chains / sprockets / cutting blades.
(d) Engines -- All engines used on Dixon ZTR mowers are warranted by each individual engine manufacturer.
(e) Any costs or expense of providing substitute equipment while repair work is being performed on a warranted mower.

7.

There is no other express warranty. Implied warranties, including those of merchantability and fitness for a particular
purpose, are limited to the same duration of the express warranty, and to the extent permitted by law any and all implied
warranties are excluded. Liabilities for consequential damages under any and all warranties are excluded.

WARRANTY VALIDATION: At the time of sale, selling dealer must review each portion of this warranty document, complete the
information section below, secure customer's signature and send copy to Dixon Industries, Inc.

Page 4

made of rotational molded polyethylene. Front body contains access

panels for battery service and engine to mower deck belt removal. Rear body

tor comfort by use of high density closed cell

12 GA stamped steel construction, 3 blades, 50" cut width, cut height approximately

10L Series 70

hydrostatic transmission. The hydrostatic transmissions, in turn, power a fully

gearbox are

permanently lubricated using a special grease which completely eliminates the

1 OL Series 70 hydrostatic transmissions are serviced with

ed by a 10 micron oil filter.

Recommended service interval for filter is after the first 250 hours of operation,

then after every 400 hours of operation. If the system becomes contaminated by

Cycle, Air Cooled, Gasoline, Twin

Cylinder Opposed, Aluminum Crankcase, Removable Cast Iron Cylinder Barrels,

key switch operation with safety interlocks on parking brake and blade

nline 10

30 motor

l

CHASSIS:

BODY:

11 GA - rectangular tube.

Two piece -

SPECIFICATIONS

tilts up to allow service on the entire drive system.

SEAT:

Economically designed for opera

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

MOWER DECK:

1" to 4" via 7 position lift handle.

BLADE DRIVE:

DRIVE SYSTEM:

Electric clutch.

Each rear wheel is independently driven by a Hydro Gear BDU-

enclosed Hydro Gear gearbox. The gears in the Hydro Gear

need for any type of maintenance.

The Hydro Gear BDU-

any high quality 10W-30 motor oil. The oil is filter

ENGINE:

STARTING SYSTEM:

TIRES:

CAPACITIES:

DIMENSIONS:

NOTE:

dirt or other foreign debris, both oil and filter must be replaced immediately.

20 HP Kohler Magnum, Vertical Crankshaft, 4-

Electronic Ignition, Full Pressure Lubrication.

Electric by
drive clutch.

Front 11 X 4.10 X 5 smooth profile.
Rear 20 X 1 0 X 8 turf savers.

Fuel - 4.8 gallons total (dual tanks). Hydrostat oil tank - 3 quart with i
micron filter. Hydrostat oil recommendation - name brand SAE 10W­oil.

Width 60"
Height 45"
Length 72"
Weight 668 Ibs.

Additional information provided in service instructions under the individua

component.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.

PageS

Page 6

SET UP AND SERVICE

1. Seat Assembly Instructions

2. Upper Control Lever Installation

3. Mower Deck Installation

4. Deck Leveling

5. Final Preparation

1.

2.

3.

4.

5.

6.

7.

8.

9.

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.

Insert (2) 5/16-18 X 5/8" tapping screws through holes in bracket & frame and start screw threads.
DO NOT TIGHTEN SECURELY.

Insert (1) 1/4-20 X 3/4" Phillips machine screw through remaining hole in bracket and start screw
threads. DO NOT TIGHTEN SECURELY.

Repeat steps 2 through 4 for the other armrest.

Tighten all screws.

Align back cover to seat back. Secure with (4) #14 X 5/8" wood screws and (4) 5/16" SAE washers

in recesses provided.

Slide armrest onto mounting bracket pin.

Insert set screw in rear of armrest, securing armrest to mounting bracket.

10.

11.

Repeat steps 8 & 9 for other armrest.

Center utility box on seat back cover and fasten with drill & tap screws and washers provided in
separate hardware package.

Page 7

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 ) 5/1 6-1 8 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
illustration. Repeat procedure for other seat strap.

13

Attach seat straps to seat bottom as illustrated.

.

The 3" stud protruding through strap must be
located near the rear of seat while the 4" stud
should be nearest the front edge of seat. Align
remaining seat strap holes with holes in bottom
of seat as shown, and attach seat straps using
(4) 5/1 6-18X1 " tapping screws.

14

Place seat assembly on body, and

.

safety switch.

15

Place (1) seat spacer (1849) on each stud

.

protruding through seat bottom, and insert studs

connect

through slots in body. Firmly hold seat assembly
against body with one hand while body is raised to
fully open position. Continue to hold seat against
body to prevent damage to seat safety switch
wiring.

16

Install (1) 5/16 standard flat washer (3020), (1)

.

seat knob (3874), and (1) nylok nut (3205) on
each of the front studs extending through body
and seat frame, and tighten these nuts.

17

Install (1) 5/16 standard flat washer (3020) and (1)

.

nylok nut (3205) on each of the rear studs. Do not
fully tighten these nuts, thus allowing for easy
slide action of seat, as provided by knobs on front
studs.

Page 8

1.

2.

3.

4.

5.

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. (See illustration)

Tighten jam nut. 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.

Repeat above procedure on left side.

Page 9

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

Loosen and remove front body mounting bolts (P/N 3368) and washers (P/N 3066).

r rods, small holes in lift

plate will face rear of mower, and start nylok nuts on each hanger rod until approximately

lift frame and tabs on

Move lift lever to lowest cut position, install engine to mower deck drive belt on top center

at belt is centered in

Page 10

NOTE:

1.

2. .

3.

4.

5.

MOWER DECK INSTALLATION

Brake link (P/N 5283) normally used for installation of engine to mower deck

DISCARD cotter pin and washer after engine to mower drive belt has been installed.

Disconnect headlight wiring plug from wiring harness. Lift front body from chassis.

Install rear hanger rods on lift frame. Slide lift plate on hange

1/2 inch of threads are exposed.

Position mower deck under chassis.

Raise front of mower deck and slide front support rod through
mower deck. Install hair pin clips on front and rear of support rods.

pulley. Check belt routing after installation to make certain th
groove of electric clutch pulley.

6.

7.

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

Install front body, connect headlight wiring.

MOWER DECK LEVELING PROCEDURE

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

ck 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.

in front to rear 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

surement. 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

Page 11

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.

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 - 19 - 21 Ibs maximum Rear- 10­14 Ibs maximum

B.

Rotate or turn each outer blade tip to align with the edge of the deck or side to side.

C.

mower deck. Retain this measurement. Move to the opposite side, che

Retain measurement.

D.

Rotate or turn both outer blades to align with the deck

1/8th of an inch higher than the side to side mea

used on the left rear of the deck.

NOTEThis 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.

MOWER DECK DEFLECTOR:

check that the pressure relief bypass on each hydrostatic transmission is completely

Each hydrostat has a bypass relief pin located at the rear of the hydrostatic unit. A

he mower to be rolled around without complete

servicing of the unit. To accomplish this, the bypass keeper springs must be positioned

to depress the bypass relief pins. Remove bypass keeper springs prior to actual

Remove hair pin cotter (P/N 3072) from deflector pin (P/N 6402), remove pin. Position
deflector (P/N 9264) on mower deck. Reinstall deflector pin and hair pin cotter.

BATTERY:

FINAL PREPARATION

1.

2.

3.

4.

Remove battery from chassis.

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

Allow battery to sit for (1 0) minutes, re-check acid level and top off any cells that are low.

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:

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

released before attempting to drive mower.

2.

bypass keeper is provided to allow t

operation of the mower.

Page 12

OPERATION INSTRUCTIONS

The safe and successful operation of the Model 5501 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.

Sound judgement by the owner will prevent accidents. All

controls are described from operators position:

PARKING BRAKE:

The parking brake used on the Model 5501 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.

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 push 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 the 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.

Page 13

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
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.

THROTTLE CONTROL LEVER:

Controls engine speed, slow to maximum. Lever should be set to the maximum
or wide open setting to insure adequate cooling of the engine and to maintain
mower deck blade speed while mowing.

MOWER 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
non-mowing 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".

CIRCUIT BREAKER:

Protection of the electrical system is by (1) 15 amp circuit breaker. If circuit
breaker engages, push button to reset. If this condition repeats, consult dealer
for inspection and repair.

Page 14

CARE AND MAINTENANCE - MODEL 5501

2.

Mower deck belts.

This portion of the Model 5501 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: Due to the precision nature of the hydrostatic transmissions used on the Model

5501, internal service repairs cannot be recommended. Current service
requirements will necessitate replacement of an entire hydro unit if failure
should occur.

MAINTENANCE SCHEDULE:

To insure a long and trouble free service life on all the components used on the
Model 5501 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:

Drive system, belts and controls.

3.

4.

5.

6.

Tire pressures.

Hydrostat oil.
Tightness of all nuts and bolts.
Electric blade clutch air gap setting.
* Refer to Page 16 for details

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

Page 15

2. Locate the three rivet joints which fasten the leaf springs to the

as necessary to achieve a consistent .012 inch air gap.

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 maintenance procedures to extend the life of
the clutch as they wear over time. Below is the information to make these maintenance adjustments
and also a procedure to check for a faulty coil. In the case that the clutch has failed a part, the entire
clutch must be replaced since there are no parts available.

A. AIR GAP ADJUSTMENT

1. Remove the clutch from the engine. This is recommended because it is easier to verify the
gap.

armature (figure 1).

3. Rotate the pulley until these rivet joints are located midway along
the edge of the triangular field adapter (figure 1).

4. Locate the three holes in the brakeplate, one near each
adjustment nut (figure 2).

5. Insert a .012 inch feeler gauge into one of the three windows.
Be careful to position the feeler gauge between the rotor and
armature faces (figure 3).

figure 1

6. Tighten the adjusting nut adjacent to the window with the feeler gauge inserted until the gauge

fits snugly between the rotor and armature. The gap should not be so tight that the feeler gauge
cannot be reinserted after removal.

7. Repeat Steps 5 and 6 at the other two windows.

8. Re-check the air gap at each window and make minor adjustments

9. Reinstall the clutch to the engine. Be sure to torque the mounting
bolt back to 50 ft. Ibs.

B. OHMS TEST:

1. Disconnect clutch from mower wiring harness which is located

on the right side of the mower frame.

2. Set the multi-meter on RX1 and attach the two leads to the two

wires coming from the electric clutch.

3. The reading you receive should be between 2.4 to 2.9 OHMS.

4. If the resistance is outside this range the clutch coil is faulty.

5. If the clutch coil is faulty, the clutch must be replaced.

Page 16

CARE AND MAINTENANCE - MODEL 5501

Remove front belt access cover from body. Stand in front of mower, grasp lift quadrant

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

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

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.

lding onto cutter blade, avoid the sharp

When reassembling blades to hub assemblies, fully tighten blade bolts to a minimum

of 60 ft. Ibs. torque. The use of air impact tools is recommended for installation to insure

The engine to mower deck drive belt on the Model 5501 is automatically held in proper

tension by springs which push the deck assembly forward, and does not require any

idler system should be

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

nsure cut

quality. If adjustment is required, tighten lock nut on adjustment rod until belt free play

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 A/OTattempt
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 necessary equipment, entrust this
task to your dealer.

DECK REMOVAL:

1.

lever with left hand. Move lever to align

cut position and remove belt from the top of center deck hub assembly.

2.

Remove the hair pin cotters from the

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.

"Caution" wear heavy, thick gloves when ho
edge of the blade. - —

2.

bolt tightness.

BELT TENSION:

1.

additional adjustment to be made. Both the belt and the
periodically inspected due to the nature of the job they perform.

2.

on the top of the mower deck assembly. Proper belt tension is critical to i

or movement between pulleys is approximately 1/4 of an inch.

Page 17

CARE AND MAINTENANCE - MODEL 5501

drive system is limited to the actual function of the hydrostatic

box mounting plate until each belt has 1/8th to 1/4th of

3. Neutral adjustment. Swing upper control levers out into the neutral slots. Raise upper

g brake. Caution

to

and

is

4. Forward travel speed adjustments. Stop engine, move levers to drive position, lightly

ance is felt on the lever. At this time,

If

the

adjust lever stop on

UP

IN

set following this

DRIVE SYSTEM ADJUSTMENTS:

Adjustment of the
transmissions as outlined below.

1 . Tighten the (2) J-bolts on the T-

an inch free play or movement at a mid-point between the pulleys on the hydrostats and T­box.

2. 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 loss of power.

body to the fully open position. Start engine and disengage parkin
should be used when releasing parking brake as mower may tend to creep or move prior
adjustment. If adjustment is required, loosen lock nuts at each end of the control rods
back off the tension on each spring block. Turn control rods in or out until neutral
obtained on each hydrostat. Re-tighten lock nuts and tension bolts on spring blocks.

push each upper control lever forward until a resist
check that the forward lever stops on the bottom of each lever are hitting the stop blocks.
adjustment is required, loosen the lock nuts on the lever stop and turn the bolt in until
lever hits the stop block before resistance is felt in the hydrostat.

5. Balance of travel speed. If mower tends to pull to either side, re­fast side to slow the hydrostat down and even out the ground speed. DO NOT SPEED
THE SLOW SIDE, AS OVER STROKING OF THE HYDROSTAT COULD RESULT
DAMAGE TO THE UNIT. If upper control levers are slightly off­adjustment, they can be realigned by bending them slightly.

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

Page 18

ADJUSTMENT POINTS FOR T-BOX BELT TENSION

Page 19

FORWARD LEVER STOP ADJUSTMENT

Page 20

CARE AND MAINTENANCE - MODEL 5501

CHASSIS AND MOWER DECK:

LOCATIONS:

SERVICE INTERVALS:

RECOMMENDED GREASE:

CAUTION: The use of compressed air pressure greasing methods is

LUBRICATION

Number of grease zerks used: (7)

(1) each front wheel caster, front wheel, and deck hub for
front wheels

Every 50 hours of operation

Name brand wheel bearing or multi-purpose grease

not recommended as damage to seals and bearings could
occur.

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

ENGINE OIL CHANGES:
OIL RECOMMENDATIONS:

"Refer to separate owners manual furnished by the
engine manufacturer."

SERVICE INTERVALS:

PLEASE DISPOSE OF USED OILS AT PROPER COLLECTION CENTERS.

PROTECT YOUR ENVIRONMENT

Page 21

CARE AND MAINTENANCE - MODEL 5501

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. A better approach is the use of the 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. To remove excess water which accumulated 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

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 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 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 maximum

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

Poor cut quality Improper blades

Replace with original equipment
blades which are designed for the
Model 5501

Poor cut quality Uneven tire pressures

Check and adjust as required per
operators manual

Page 23

TROUBLESHOOTING

DRIVE SYSTEM:

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

Poor driving

performance

Oil leaks

Drive adjustment

T-Box belts slipping

Belt from engine to
T-Box is slipping

Operation of mower

Loose or missing
hose clamps

Adjust per operators manual
Consult your dealer for repair

Adjust per operators manual
Consult your dealer for repair

Adjust per operators manual
Consult your dealer for repair

Review operators section

of owners manual

Tighten or replace as required

Page 24

TROUBLESHOOTING

ELECTRICAL SYSTEM:

SITUATION CAUSES REMEDY

Starter will not
turn engine over

Starter will not
turn engine over

Battery discharge

Battery discharge

Battery discharge

Circuit breaker engaged

Push button to reset Consult

your dealer for repair

Dead battery Charge battery

Poor connections on

Tighten or replace as required
battery Battery water low
Wrong battery installed
in mower

Engine electrical system
not functioning correctly

Engine being operated

at too low an RPM

Have electrical system checked by

your dealer

Increase engine RPM Contact your

dealer for information

Electric clutch will
not engage mower
deck blades

Low battery condition
Poor connections on
clutch switch Broken

Repair or replace as required

Consult your dealer for repair

wiring

NOTE: 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.

Page 25

Page 26

Page 27

Page 28

Page 29

Page 30

Page 31

Page 32

1300

Drive Belt

3

100 7/16" HD Flat Washer

1682

L-Rod

3160

5/16" Flat Washer

1714

T-Box Drive Belt

3178

3/8"

-

16X21/2"HH Bolt GR5

1895

Clutch Anchor

3220

7/16"

-

20 X 2 3/4" HH Bolt GR5

2995

Commercial Decal

3227

5/16"

-

18X2" HH BoltGR5

3007

1/4"

-

20 UNC Hex Nut

3243

5/16"

-

18X31/4"HHBoltGR5

3009

5/16"

-

18 UNC X 1 3/4" HH Bolt GR8

3248

5/1 6" ID X 1/8" Thick Washer

3020

5/16" Std Flat Washer

3257

7/16" Int Tooth Lock Washer

3052

3/32" X 1 " Cotter Pin

3266

1/4" Int Tooth Lock Washer

3066

3/16" Std Flat Washer

3269

5/1 6"

-

18X1" Soc Hd Bolt

3087

5/16"

-

18 UNC X 3/4" HH Bolt GR5

3298

Washer .51 5 X. 874 X. 031

ZTR 5501 PARTS LIST

1384 Tank Mount Bracket (Short) 3106 1/4"X1"Spirol Pin
1385 Tank Mount Bracket (Long) 3130 1/2" Contact Belleville Spring

1657 Spring - Belt Idler 3140 1/4" ID Disc Spring

1687 Idler Pulley 3161 5/1 6"-24UNFLH Thread
1701 Wheel/Deck Hub Bearing 3163 1/2" Int Tooth Lock Washer

1715 Rear Wheel & Tire 3182 Flip Lock Bushing
1732 Pulley - T-Box 3187 #10-32 Hex Nut
1733 Pulley - T-Box Drive 3188 #10 Ext Tooth Lock Washer
1734 Pulley - Hydrostat 3195 Face Nut 1/2"-27

1739 Hydrostat Idler Bracket 3196 Face Nut 7/1 6"-28
1743 Hydrostat Flat Idler Pulley HD 3203 3/8" ID Flat Washer (Narrow)
1745 Pulley 3204 1/4"-20HexNutw/Nylok
1763 Tie Down w/lnsulator 3205 5/16"-18HexNutw/Nylok
1765 V-Belt 3206 3/8"-16HexNutw/Nylok
1834 Seat Strap 3207 1/2"-13HexNutw/Nylok
1849 Seat Spacer 3208 #10-24 Hex Nut w/Nylok

2128 Sleeve 3224 5/16"-18 X 1" HH Bolt w/Nylok GR5
2928 3/1 6" X1" Key 3225 3/8"-16X2 1/4" HH Bolt

3002 5/16"-18X21/2"HHBoltGR8 3231 9/1 6" Std Flat Washer
3005 5/16"-18UNCHexNut 3235 #1 0-24 X 5/8" Phillips Pan HD Screw
3006

5/16"-18X14"HHBoltGR5

3237 Eye Bolt 5/1 6" X 6.00"

3008 1/4" ID X 3/4" OD Flat Washer 3247 #6-20 X 1/2" Phillips Pan Hd Screw

3012 3/8"-16UNCHexNut 3249 5/8" Int Tooth Lock Washer
3014 1/4"-20 UNC X 3/4" HH Bolt GR5 3256 Snap Ring

3023 1/4" Helical Lock Washer 3260 1/4"-20 X 1/2" HH Bolt GR5
3033 1/2" SAE Flat Washer 3264 5/16" Disc Spring HD
3048 3/8"-16UNCX1 1/2"HHBolt 3265 #10-24 X 3/4" Truss Hd Phillips Screw

3057 3/8" Std Flat Washer 3267 5/16"-18 X 1 3/8" HH Bolt GR5
3061 5/16"-18 UNC 1 3/4" Soc Set Screw 3268 3/8"-24 X 1 1/4" HHB GR8 w/Nylok

3068 1/8"X1" Cotter Pin 3272 5/16" Int Tooth Lock Washer
3072 1/8" X 1 3/4" Hair Pin Cotter 3273 8-1 8 X 3/8" Phillips Pan HD
3074 5/16"-24UNFHexJamNut 3297 1/2"-13Thin Profile Nylok

3088 1/4"-20X1"HHBoltGR5 3300 Foam Pad
3093 5/16"-18 UNC X 1" HH Bolt GR5 3310 5/16"-18Thin Profile Nylok

Page 33

ZTR 5501 PARTS LIST

3318

3/8"

-

16X2 1/4" H

H Bolt GR8

3655

Floor Pad Left Rear

3321

3669

Decal

-

Caution

3343

Hub Bolt

-

Drilled

3773

LH Rod End

3352

3/8"

-

16X1 1/4" HH Bolt GR5

3829

Fuel Line 33"

3360

5/16"

-

18 X 4" HH Bolt GR5 Alt Head

3857

Fuel Line 23"

3375

L-Rod 3.5"

3896

Hub Cover

3600

Rebound Mount

3963

Model Decal 5501

3635

Tee

-

Fuel Line

4198

Blade Drive Clutch Switch

3319 Idler Shock Mount 3656 Floor Pad Right Rear

3322
3325
3326
3331
3334
3337
3338

5/16"-18X8"HHBoltGR8

5/16"-18X51/2"HHBoltGR8
3/8"-16X31/2" HH Bolt GR8
3/8"-16X4" HHBoltGRS
M6 X P1 X 8MM HH Bolt GR8.8
Nylok Nut
Retaining Ring
M8 X 1 .25 P HWH Tap Screw

3695 J-Bolt
3702 Pulley
3705 Velcro Strip - Hook
3706 Velcro Strip - Latch
3717 3/8" Hose Clamp
3718 5/8" Hose Clamp

3721 Decal - Danger
3339 Snap Ring - 5/8" 3746 Decal - Parking Brake
3342 Washer .525 X 1 .375 X .25 3772 By-Pass Keeper

3344 Grease Zerk 3774 RH Rod End
3347 Washer 1 .033 X 1 .5 X .06 3805 Hand Grip (Black)
3349 #806 Woodruff Key 3812 Ignition Nut
3351 1/4"-20 X 1/2" HWH Tap Screw 3813 Protective Cap

3356 #12-1 4X3/4" Tap Screw 3844 Decal - Hydro-Gear
3359 5/16"-18 X 3" HH Bolt GR5 Alt Head 3852 Spring

3361 Stud 1/2"-13X2" 3861 Control Panel 50"
3362 5/16"-18X1" Tap Screw 3874 Seat Knob 5/1 6"- 18
3364 Washer - Bent 3876 Caster Spring
3368 1/4"-20 X 3/4" HWH Tap Screw 3878 Caster Plug
3369 1/4"-20 U Nut 3882 Hand Grip (Notched)
3370 1/4" Square Key X 2.50" 3887 Chrome Lug Nut
3373 6-32X1/2" HWH Slotted 3889 Drive Pulley 1.13 Bore
3374 6-32 Hex Nut x/Nylok ^> ' 3890 Bearing

3391 1/8" X 1 1/2" Cotter Pin 3898 Clutch Spacer
3403 Bushing 3916 Decal - DIXON
3531 Decal - Operating Instructions 3917 Bar Sleeve
3536 Decal - Danger 3919 Hour Meter

3558 2 Gallon Tank w/Cap 3947 Fuel Cap
3578 Nylon Bushing 3948 Flip-Lok Bushing
3585 Decal - Cutting Height 3953 Nylon Bushing

3601 Load Mount 3965 L-Rod 5.5
3602 Spacer Tube 4124 Solenoid w/Hardware
3603 ISO Mount Insert 4197 Ignition Switch

3649 Fuel Line Clamp 4199 Light Switch
3653 Floor Pad Left Front 4217 Battery
3654 Floor Pad Right Front 4242 Deck Switch

Page 34

ZTR 5501 PARTS LIST

4274

Choke Cable

5585

Tab

4568

Throt

tle 5625

Gearbox

4598

Circuit Breaker

5633

5/8" Hose

-

2"

5283

Link

6260

Blade Washer

5501

Mount Plate

6402

Deflector Pin

5515

Idler Cable

8177

Caster Tire 50"

4256 Utility Box 5565 Oil Filter

4276 Headlight Assembly 5595 Hose 5/8" X 14"
4384 Relay 5602 Hose Guard Spring

4453 Access Cover Assembly 5624 Tank Cap

4584 Start Cable 5627 Left Fan
4585 Battery Ground Cable 5628 Right Fan

4589 Covered Key 5632 3/8" Hose - 5"

4645 Wire Cover 30" 5635 Reservoir Assembly
4715 Seat Switch Assembly 5636 Brass Ferrule

4757 Seat Assembly 50" 5641 G-Box Mount Spacer
4774 Battery Cable Assembly 5643 Input Gear - GB
4781 Upper Wiring Loom 5644 Bearing - Gearbox
4782 Lower Wiring Loom 5645 Bearing Spacer - GB
5070 Key 3/1 6" Sq X . 88" 5663 Electric Clutch
5085 Brake Band 6075 Engaging Idler Bracket Spacer
5087 Spacer 3/8" X 1/2" 6100 Outer Shaft Key
5170 Spring 6101 Center Shaft Key
5189 Bushing 6111 Deck Drive Belt
5257 Brake Drum (Keyed) 6168 Trash Guard

5500 T-Box 6395 Blow-By Baffle 50"

5502 Mount Shim 6406 Deflector Spring
5503 T-Box Guide Left 6744 Spring
5504 T-Box Guide Right 7034 Belt Keeper

5522 Brake Link Right 8178 Caster Rim 50"
5525 Brake Link Left 8179 Caster Bearing 50"
5530 Control Pivot Shaft 8180 Bearing Retainer 50"
5531 Adjustable Collar 8383 5501 Frame Assembly
5537 Control Arm Bracket 8384 Upper Body
5540 Neutral Adjust Collar 8385 Lower Body w/Decals
5550 Hydrostat 8387 Wiring Kit
5551 Hydrostat 8393 3/8" Black Hose 3.75
5554 Spacer 1/2" OD X 1/4" 8429 Oil Valve/Hose Assembly
5558 Hose Fitting 8432 Axle Housing Assembly

5559 Hose Fitting 8433 Hydro Mount Housing
5560 Elbow - Male 8434 Splined Reduction Gear
5561 Adapter - Male (For 3/8" ID Hose) 8435 Final Drive Gear
5562 Adapter - Male (For 5/8" ID Hose) 8436 Axle Assembly
5563 Tee - Cast Iron 8437 Ball Bearing

Page 35

ZTR 5501 PARTS LIST

8440

Ball 3/8" Diameter

9219

Deck Hub

8469

Brake Pin

9310

Caster Axle RH

8577

Rear Tire

936

6 Deck Baffle

8788

Tie Bar/Anchor Kit

9377

Brake Lever

9067

Control Rod

9655

Lift Shaft Weldment

9157

Left Swivel Plate

9164

Brake Plate

9174

Brake Rod

9192

Tie Bar

9196

Plate

8439 E-Ring 9212 Spring (Belt Tensioner)

8441 Bolt 1/2"-20 X 2 1/2" 9228 Deck Hub Bearing Spacer
8442 Washer .62 X 1 .0 X .05 9242 Pulley Guard

8443 Spring Pin 3/1 6" X 1/2" 9264 Deflector (Folding)
8444 Type "O" Grease (Tube) 9265 Hi-Lift Blade 50"
8452 42750" Battery Cover 9274 Mower Deck Assembly
8460 Deck Replacement (9273) 9280 Engine Plate
8467 Ball Bearing 9298 Caster Tube Assembly
8468 Flanged Bearing 9309 Caster Axle LH

8470 Lug Bolt 9312 Bumper Weldment
8471 Cap Plug 3/8" 9315 Caster Wheel & Tire

8472 Cap Plug 1/4" 9323 Deflector Mount Plate
8572 Headlight Bulb 9337 Shaft - Tapped (Short)
8573 Headlight Bulb Socket 9338 Shaft - Tapped (Long)
8576 Rear Rim 9362 Idler Assembly (9276)

8689 Mower Blade 50" Standard 9372 Body Brace

8791 Convuluted Loom 1/2" X 60" 9405 Deflector Mount Bracket
8853 Fuel Line 22.5" 9411 Seat Frame Weldment
8854 Fuel Line 6" 9618 Lift Handle Weldment
8855 3/8" Hose 26.5" 9623 Lift Cam Drilled RH
9023 Engine Mount Plate - Forward 9624 Lift Cam Drilled LH
9031 Spacer 9634 Lift Frame Weldment
9049 Lift Bushing Bracket 9646 Lift Plate

9082 Seat Frame Pivot Rod - '"
9098

L- Rod 9/1 6" X 15 3/16" ^
9110 Tank Cover
9156 Right Swivel Plate

9158 Control Lever w/Grip Left
9159 Control Lever w/Grip Right

9165 Brake Plate
9168 Brake Shaft Weldment
9171 Spacer 1 .75
9172 Spacer 1 .50

9175 Spring Anchor
9191 Connecting Link

Page 36

'

NOTES

Page 37

NOTES

Page 38

DIXON INDUSTRIES, INC
A BLOUNT COMPANY
AIRPORT INDUSTRIAL PARK

PO BOX 1569
COFFEYYILLE KS 67337 O945
316 251 2QOO
FAX [phone]