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 [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

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.

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

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

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 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.

Page 10

MOWER DECK LEVELING PROCEDURE

LEVELING PRINCIPALS:

A. There are a total of (4) threaded adjusters which will control the attitude or pitch of the

mower deck. The adjusters have lock nuts on the bottom which can be turned up or
down to raise or lower the front and rear of the mower deck. Deck should be level or
pitched slightly higher in rear.

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 lbs maximum
Rear- 10 -14 lbs maximum

B. 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, 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 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
1 /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.

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.

Page 11

FINAL PREPARATION

Page 12

MOWER DECK DEFLECTOR:

Remove hair pin cotter (P/N 3072) from deflector pin (P/N 6297), remove pin. Position
deflector (P/N 8799) on mower deck. Reinstall deflector pin and hair pin cotter.

BATTERY:

1. Remove battery from chassis.

2. Fill each cell with 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:

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 rear of the hydrostatic unit. A
bypass keeper is provided to allow the 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
operation of the mower.

OPERATION INSTRUCTIONS

Page 13

The safe and successful operation of the Model 560 will depend upon the operator having the
correct knowledge of all controls used on the mower and making good judgements about the
terrain to be mowed. NEVER allow anyone to operate the mower without complete knowledge
of all controls and their functions.

Sound judgement by the owner will prevent accidents. All

controls are described from operators position:

PARKING BRAKE:

The parking brake used on the Model 560 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 112 hour should be spent simply driving the mower in a non-mowing
application to gain the confidence neccessary 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.

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 560

Page 15

This portion of the Model 560 owners manual deals with normal service items which can be
performed by the owner. Please remember that if you are in doubt as to the correct service
procedures to be followed, these and other service situations can be handled by a Dixon ZTR
Dealer who is familiar with the service of your mower.

NOTE: Due to the precision nature of the hydrostatic transmissions used on the

Model 560, 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 560 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, belts and controls.

2. Mower deck belts.

3. Tire pressures.

4. Hydrostat oil.

5. Tightness of all nuts and bolts.

6. 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.

PROCEDURE FOR ELECTRIC CLUTCH ADJUSTMENT

2. Locate the three rivet joints which faste

n the leaf springs to the

Dixon has used two types of electric clutches. One type is the Borg Warner and the second one is the
Ogura. Even though these clutches come from different manufacturers, the test procedures are the
same for both. Few people realize that clutches have maintainance procedures to extend the life of
the clutch as they wear over time. 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).

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. Recheck the air gap at each window and make minor adjustments
as necessary to achieve a consistent .012 inch air gap.

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

B. OHMS TEST:

1. Disconnect clutch from mower wiring harnass 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 560

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. Remove front belt access cover from body. Stand in front of 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 reassembling blades to hub assemblies, fully tighten blade bolts to a minimum
of 50 ft. lbs. torque. The use of air impact tools is recommended for installation to insure
bolt tightness.

BELT TENSION:

1. The engine to mower deck drive belt on the Model 560 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 17

CARE AND MAINTENANCE - MODEL 560

DRIVE SYSTEM ADJUSTMENTS:

Adjustment of the drive system is limited to the actual function of the hydrostatic
transmissions as outlined below.

1. Tighten the (2) J-bolts on the T-box mounting plate until each belt has 1/8th to 1/4th of
an inch free play or movement at a mid-point between the pulleys on the hydrostats and
T-box.

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.

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

4. Forward travel speed adjustments. 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 on the bottom of each lever are hitting the stop blocks.
If adjustment is required, loosen the lock nuts on the lever stop and turn the bolt in until
the 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, re-adjust lever stop on
fast side to slow the hydrostat down and even out the ground speed. DO NOT SPEED
UP THE SLOW SIDE, AS OVER STROKING OF THE HYDROSTAT COULD RESULT
IN DAMAGE TO THE UNIT. If upper control levers are slightly off-set following this
adjustment, 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 18

FORWARD LEVER STOP ADJUSTMENT

Page 20

CARE AND MAINTENANCE - MODEL 560

:

LUBRICATION:

CHASSIS AND MOWER DECK: Number of grease zerks used: (7)

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

front wheels

SERVICE INTERVALS: Every 50 hours of operation

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

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
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: "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

CARE AND MAINTENANCE - MODEL 560

Page 22

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.

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 560

Poor cut quality Uneven tire pressures

Check and adjust as required per
operators manual

Page23

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

Dead battery

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

Engine electrical system
not functioning correctly

Engine being operated

at too low an RPM

Push button to reset Consult

your dealer for repair

Charge battery

Tighten or replace as required

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.

Page25

1714

T-Box Drive Belt

3161

5/16"-

24UNFLH Thread

1752

Plastic Idler 4"

Flat 3195

Face Nut 1/2"

-

27

3002

5/16"

-

18X21/2"HHBGR8

3

225 3/8"

-

16X21/4"HHBolt

3009

5/16"

-

18 UNC X 1 3/4" HH Bolt GR8

3243

3020

5/1 6" Std Flat Washer

3248

5/1 6"

ID X 1/8" Thick Washer

3048

3/8"

-

16UNCX1 1/2" HH Bolt

3257

7/16" Int Tooth Lock Washer

3066

3/1 6" Std Flat Washer

3266

1/4" Int Tooth Lock Washer

3074

5/16"

-

24UNFHexJamNut

3269

5/1 6"

-

18X1" Soc Hd Bolt

ZTR 560 PARTS LIST

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

1715 Rear Wheel & Tire 3163 1/2" Int Tooth Lock Washer
1732 Pulley - T-Box 3169 3/8"-16X1"HHBoltGR5
1733 Pulley - T-Box Drive 3178 3/8"-16X2 1/2" HH Bolt GR5
1734 Pulley - Hydrostat 3182 Flip Lock Bushing
1739 Hydrostat Idler Bracket 3186 #12-14 X 1" Drill & Tap Screw
1743 Hydrostat Flat Idler Pulley HD 3187 #10-32 Hex Nut
1745 Pulley 3188 #10 Ext Tooth Lock Washer

1763 Tie Down x/lnsulator 3196 Face Nut 7/1 6"-28
1765 V-Belt 3201 Washer .533 ID X1. 37 OD
1834 Seat Strap 3203 3/8" ID Flat Washer (Narrow)
1849 Seat Spacer 3204 1/4"-20 Hex Nut x/Nylok
1895 Clutch Anchor 3205 5/16"-18HexNutw/Nylok
1911 Roller Bracket Weldment 3206 3/8"-16HexNutw/Nylok
1917 Rear Roller Bracket Weldment 3207 1/2"-13HexNutw/Nylok

2128 Sleeve 3208 #10-24 Hex Nut w/Nylok
2928 3/1 6" X1" Key 3224 5/16"-18 X 1" HH Bolt w/Nylok GR5

3005 5/16"-18UNCHexNut 3227 5/16"-18X2"HHBoltGR5
3006 5/16"-18X 1/4" HH Bolt GR5 3231 9/1 6" Std Flat Washer
3007 1/4"-20 UNC Hex Nut 3235 #10-24 X 5/8" Phillips Pan HD Screw

3008 1/4" ID X 3/4" OD Flat Washer 3237 Eye Bolt 5/1 6" X 6.00"

5/16"-18X31/4"HHBoltGR5

3012 3/8"-16UNCHexNut 3245 3/8"-16 Thin Profile Nylok Nut
3014 1/4"-20 UNC X 3/4" HH Bolt GR5 3247 #6-20 X 1/2" Phillips Pan Hd Screw

3023
3033

1/4" Helical Lock Washer
1/2" SAE Flat Washer

3052 3/32" X1" Cotter Pin 3260 1/4"-20X1/2"HHBoltGR5
3057 3/8" Std Flat Washer 3264 5/16" Disc Spring HD
3061 5/16"-18 UNC 1 3/4" Soc Set Screw 3265 #10-24 X 3/4" Truss Hd Phillips Screw

3068 1/8"X1" Cotter Pin 3267 5/16"-18X1 3/8" HH Bolt GR5
3072 1/8" X 1 3/4" Hair Pin Cotter 3268 3/8"-24 X 1 1/4" HHB GR8 w/Nylok

3087 5/1 6"- 18 UNC X 3/4" HH Bolt GR5 3272 5/16" Int Tooth Lock Washer
3088 1/4"-20X1"HHBoltGR5 3273 8-1 8 X 3/8" Phillips Pan HD

3249 5/8" Int Tooth Lock Washer
3256 Snap Ring

Page33

ZTR 560 PARTS LIST

3298

Washer .51 5 X. 874 X. 031

3601

Load Mount

3318

3/8"

-

16X2 1/4"HHBoltGR8

3635

Tee

- Fuel Line

3325

3653

Floor Pad Left Front

3331

M6XP1 X8MMHHBGR8.8

3655

Floor Pad Left Rear

3352

3/8"

-

16X1 1/4" HH Bolt GR5

3774

RH Rod End

3297 1/2"-13Thin Profile Nylok 3600 Rebound Mount

3300 Foam Pad 3602 Spacer Tube
3310 5/16"-18Thin Profile Nylok 3603 ISO Mount Insert

3319
3321
3322

3326

3334

Idler Shock Mount

5/16"-18X8"HHBoltGR8
5/16"-18X51/2"HHBGR8
3/8"-16X31/2"HHBGR8
3/8"-16X4"HHBGR8

Nylok Nut

3644 Fuel Line 7 1/2"
3646 Fuel Line 20"
3649 Fuel Line Clamp

3654 Floor Pad Right Front

3656 Floor Pad Right Rear
3337 Retaining Ring 3669 Decal - Caution
3338 M8 X 1 .25 P HWH Tap Screw 3695 J-Bolt
3339 Snap Ring - 5/8" 3702 Pulley
3342 Washer .525 X 1 .375 X .25 3705 Velcro Strip - Hook
3343 Hub Bolt-Drilled 3706 Velcro Strip - Latch
3344 Grease Zerk 3717 3/8" Hose Clamp
3346 1/8" DiaX1 1/4" Cotter Pin 3718 5/8" Hose Clamp
3347 Washer 1. 033X1. 5 X. 06 3721 Decal Danger
3348 5/1 6"-1 8X3/4" Tap Screw 3746 Decal - Parking Brake
3349 #806 Woodruff Key 3772 By-Pass Keeper
3351 1/4"-20 X 1/2" HWH Tap Screw 3773 LH Rod End

3356 #12-1 4X3/4" Tap Screw 3805 Hand Grip - Black
3359 5/16"-18 X 3" HHB GR5 Alt Head 3812 Ignition Nut
3360 5/16"-18 X 4" HHB GR5 Alt Head 3813 Protective Cap
3361 Stud 1/2"-1 3X2" 3844 Decal - Hydro-Gear

3364 Washer - Bent 3852 Spring
3368 1/4"-20 X 3/4" HWH Tap Screw 3861 Control Panel 50"
3369 1/4"-20 U Nut 3876 Caster Spring
3370 1/4" Square Key X 2.50" 3878 Caster Plug
3373 6-32 X 1/2" HWH Slotted 3882 Hand Grip (Notched)
3374 6-32 Hex Nut w/Nylok 3887 Chrome Lug Nut
3375 L-Rod 3.5" 3889 Drive Pulley 1.13 Bore
3376 L-Rod 5" 3890 Bearing
3377 Serpentine Idler Spacer 3896 Hub Cover
3379 1/2"-13X3"HHBGR5 3898 Clutch Spacer
3380

7/16"-20X31/4"HHBGR5

3916 Decal - DIXON
3403 Bushing 3917 Bar Sleeve

3531 Decal - Operating Instructions 3919 Hour Meter
3536 Decal - Danger 3938 Deflector Spring
3558 2 Gallon Tank w/Cap 3947 Fuel Cap
3578 Nylon Bushing 3948 Flip-Lok Bushing
3585 Decal - Cutting Height 3952 Model Decal - 560

Page 34

ZTR 560 PARTS LIST

4198

Blade Driv

e Clutch Switch

5560

Elbow

-

Male

4242

Deck Switch

5563

Tee

-

Cast Iron

4274

Choke Cable

5565

Oil Filter

4568

Throttle

5625

Gearbox

4598

Circuit Breaker

5633

5/8" Hose

-

2"

Lower Wiring Loom

Bearing

-

Gearbox

Bushing

Trash Guard

5283

Link

6291

Deck Roller

Idler Cable

Serpentine Belt

5525

Brake Link Left

8177

Caster Tire

-

50"

3955
4124
4197

4199
4217

4256

4276
4384
4453

4584
4585
4589
4594

4645
4715
4728
4757
4773

4774
5070
5085
5087
5170
5189

5257

5500
5501
5502
5503
5504
5515
5522

5530
5531
5537
5540
5550
5551

Clutch Spacer 5554 Spacer 1/2" ODX 1/4"
Solenoid w/Hardware 5558 Hose Fitting
Ignition Switch 5559 Hose Fitting

Light Switch
Battery

Utility Box

Headlight Assembly
Relay
Access Cover Assembly

Start Cable
Battery Ground Cable
Covered Key
Wiring Cover 14"

Wire Cover 30"
Seat Switch Assembly
Upper Wiring Loom
Seat Assembly 50"

Battery Cable Assembly
Key 3/1 6" Sq X . 88"
Brake Band
Spacer 3/8" X 1/2"
Spring

Brake Drum (Keyed)

T-Box
Mount Plate
Mount Shim
T-Box Guide Left
T-Box Guide Right

Brake Link Right

Control Pivot Shaft
Adjustable Collar
Control Arm Bracket
Neutral Adjust Collar
Hydrostat
Hydrostat

5561
5562

5564

5585
5602
5624

5627
5628
5631
5632

5635
5636
5641
5643
5644

5645

5661

6075
6100

6101

6168

6260

6293
6297
6367
6744
6938
6939
7034

8178
8179
8180
8294
8384
8385

Adapter - Male (For 3/8" ID Hose)
Adapter - Male (For 5/8" ID Hose)

Filter Head

Tab

Hose Guard Spring

Tank Cap

Left Fan

Right Fan
3/8" Hose -21"
3/8" Hose - 5"

Reservoir Assembly

Brass Ferrule
G-Box Mount Spacer

Input Gear - GB

Bearing Spacer - GB
5/8" X 12.5" ID Black Hose

Engaging Idler Bracket Spacer
Outer Shaft Key
Center Shaft Key

Blade Washer

Deflector Mount Bracket
Deflector Pin
Roller Shaft
Spring
V-Belt, Deck Drive

Belt Keeper

Caster Rim - 50"
Caster Bearing - 50"
Bearing Retainer - 50"
Fuel Line 35 1/2"
Upper Body
Lower Body W/Decals

Page35

ZTR 560 PARTS LIST

8435

Final Drive Gear

9196

Plate

8440

Ball 3/8" Diamete

r 9309

Caster Axle LH

8469

Brake Pin

9377

Brake Lever

8484

Frame Weldment

-

560

9385

Belt Guard LH

8576

Rear Rim

9615

Lift Shaft Weldment

9067

Control Rod

9640

Roller Bracket Weldment

9157

Left Swivel Plate

9164

Brake Plate

8387 Wiring Kit 9171 Spacer 1 .75
8404 Clutch Kit 9172 Spacer 1 .50
8429 Oil Valve/Hose Assembly 9174 Brake Rod
8432 Axle Housing Assembly 9175 Spring Anchor
8433 Hydro Mount Housing 9191 Connecting Link
8434 Splined Reduction Gear 9192 Tie Bar

8436 Axle Assembly 9212 Spring (Belt Tensioner)
8437 Ball Bearing 9228 Deck Hub Bearing Spacer
8438 Brake Shaft 9280 Engine Plate
8439 E-Ring 9298 Caster Tube Assembly

8441 Bolt1/2"-20X21/2" 9310 Caster Axle RH
8442 Washer .62 X 1 .0 X .05 9312 Bumper Weldment
8443 Spring Pin 3/1 6" X 1/2" 9315 Caster Wheel & Tire
8444 Type "O" Grease (Tube) 9325 Seat Frame Weldment
8452 42"/50" Battery Cover 9337 Shaft - Tapped (Short)
8467 Ball Bearing 9338 Shaft - Tapped (Long)
8468 Flanged Bearing 9372 Body Brace

8470 Lug Bolt 9381 Mower Deck Weldment
8471 Cap Plug 3/8" 9382 Mower Deck Assembly

8472 Cap Plug 1/4" 9383 Hi-Lift Blade

8572 Headlight Bulb 9386 Belt Guard RH
8573 Headlight Bulb Socket 9388 Deck Pulley 6.25

8577 Rear Tire 9618 Lift Handle Weldment
8788 Tie Bar/Anchor Kit 9623 Lift Cam Drilled RH
8791 Convoluted Loom 1/2" X 60" 9624 Lift Cam Drilled LH
8799 60" Deflector w/Decal 9631 Hub Weldment Machined
9023 Engine Mount Plate - Forward 9633 Serpentine Idler Assembly
9031 Spacer 9634 Lift Frame Weldment
9049 Lift Bushing Bracket 9638 Deflector Hinge

9082 Seat Frame Pivot Rod 9646 Lift Plate
9098 L-Rod9/16"X153/16" 9651 Deflector Bracket
9110 Tank Cover 9652 Blow-by Baffle

9156 Right Swivel Plate

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

9165 Brake Plate
9168 Brake Shaft Weldment

Page 36

NOTES

Page 37

NOTES

Page 38

DIXON INDUSTRIES, INC
A BLOUNT COMPANY
AIRPORT INDUSTRIAL PARK
PO BOX 1569
COFFEYVILLE KS 67337 O945
316 251 2OOO
FAX [phone]