Dixon 560 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 560 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 O945 316 251 2OOO FAX 316 251 4117

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

SAFETY

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

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

over or backed over by the

h 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

off. Mow across the slope to slightly uphill. Mow slopes when

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

near them. Always allow the mower to

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

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...

run th engine off when cleaning or working around the mower deck.

This situation occurs when a bystander is runmower. The most frequently cited examples are wit

an adult. Always look behind you before backing up.

a dropthe

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:

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.

Most accidents of this type occur during re-

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

to operate the mower in any manner or to ride as a passenger.

Page 1

SAFETY

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-off s.

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.

Note: 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. Before adjusting or servicing your mower, turn off the engine and let it cool. Be sure all moving parts are stopped. Never run the 560 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.

Page 2

SAFETY REMINDERS:

14.

15.

16.

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. B. Limit loads to those you can safely control. C. Do not turn sharply. Use care when backing.

17.

18.

19.

20.

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.

(Continued)

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.

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.

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

SPECIFICATIONS

CHASSIS:

BODY:

SEAT:

MOWER DECK:

BLADE DRIVE:

DRIVE SYSTEM:

11 GA - rectangular tube.

Two piece - made of rotational molded polyethylene. 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.

Economically designed for operator comfort by use of high density closed cell

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

11 GA stamped steel construction, 3 blades, 60" cut width, cut height 1 " to 4" via

7 position lift handle. Self cleaning design, aides discharge of grass.

Electric clutch.

Each rear wheel is independently driven by a Hydro Gear BDU-10L Series 70 hydrostatic transmission. The hydrostatic transmissions, in turn, power a fully enclosed Hydro Gear gearbox. The gears in the Hydro Gear gearbox are permanently lubricated using a special grease which completely eliminates the need for any type of maintenance. The Hydro Gear BDU-1 OL Series 70 hydrostatic transmissions are serviced with any high quality 10W-30 motor oil. The oil is filtered 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 dirt or other foreign debris, both oil and filter must be replaced immediately.

ENGINE:

STARTING SYSTEM:

TIRES:

CAPACITIES:

DIMENSIONS:

NOTE:

20 HP Kohler Magnum, 4-Cycle, air-cooled, gasoline, vertical shaft, twin cylinder opposed, aluminum crankcase, removable cast-iron cylinder barrels, L-head.

Electric by key switch operation with safety interlocks on parking brake and blade drive clutch.

Front 11 X 4.10 X 4 ribbed tread. Rear 20 X 1 0 X 8 turf savers.

Fuel - 4.8 gallons total (dual tanks). Hydrostat oil tank - 3 quart with inline 10 micron filter. Hydrostat oil recommendation - name brand SAE 10W-30 motor oil.

Width 72" Height 45" Length 73 1/2" Weight 685 lbs.

Additional information provided in service instructions under the individual component.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.

Page 5

SET UP AND SERVICE

1. Seat Assembly Instructions

2. Upper Control Lever Installation

3. Mower Deck Installation

4. Deck Leveling

5. Final Preparation

Page 6

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 15/8" 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 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) 5/16-18 X 1" tapping screws.

14. Place seat assembly on body, and

connect safety switch.

15. Place (1) seat spacer (1849) on each stud protruding through seat bottom, and insert studs 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.

1 6. Install (1 ) 5/1 6 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

UPPER CONTROL LEVER INSTALLATION

Page 9

1. Raise rear body cover to fully open 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. 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.

5. Repeat above procedure on left side.

MOWER DECK INSTALLATION

NOTE: Brake link (P/N 5283) normally used for installation of engine to mower deck drive belt,

has been placed in position during assembly of the lift frame at the factory. For shipment purposes, the brake link has been secured with a cotter pin and washer. REMOVE AND DISCARD cotter pin and washer after engine to mower drive belt has been installed.

1. Loosen and remove front body mounting bolts (P/N 3368) and washers (P/N 3066). Disconnect headlight wiring plug from wiring harness. Lift front body from chassis.

2. Install rear hanger rods on lift frame. Slide lift plate on hanger rods, small holes in lift plate will face rear of mower, and start nylok nuts on each hanger rod until approximately 1/2 inch of threads are exposed.

3. Position mower deck under chassis.

4. 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 of support rods.

5. 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.

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

7. Install front body, connect headlight wiring.

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