Dixon 501 Lawn Mower Operation Instructions

1. SAFETY

2. WARRANTY POLICY

3. SPECIFICATIONS

4. SET UP AND SERVICE

5. OPERATION INSTRUCTIONS

6. CARE AND MAINTENANCE

7. TROUBLESHOOTING

8. PARTS ILLUSTRATIONS

9. PARTS LIST

10. ELECTRICAL SCHEMATIC

INDEX

Pages 1 - 3

Page 4

Page 5

Pages 6 - 1 1

Pages 12-13

Pages 14 -21

Pages 22 -24

Pages 25 - 28

Pages 29 - 31

Page 32

IMPORTANT - READ CAREFULLY

The Dixon ZTR Mower is both easy and fun to operate. However, any power mower must be operated properly to be safe. It is not a toy or a recreational vehicle. Before you start to use the mower, read the operator's manual carefully, and become completely familiar with the controls.

The information in this operator's manual applies to all Dixon ZTR Model

501 Mowers. Your Dixon dealer will gladly provide a check-out ride, and answer any questions.

See your dealer for warranty service, parts and repairs.

DIXON INDUSTRIES, INC.

Box 494

Coffeyville, Kansas 67337-0494

Page 1

SAFETY

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

The following examples are the most, common causes of Injury to the operator or

1. BLADE CONTACT: The operator or bystander inserts a hand or foot into the discharge chute or under the mower deck and into the path of the cutting blade.

Never run the mower blades when there are people nearby.

Always turn the engine off when cleaning or working around the mower deck.

2. RUN-OVER: This situation occurs when a bystander is run-over or backed over by the mower. The most frequently cited examples are with small children who wander into, or are allowed to play, in an area where the mower is being operated.

Never run the mower blades when there are people nearby, especially children.

Young children should be indoors and watched by an adult.

Always look behind you before backing up.

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

This situation is due to operation of the mower on steep inclines or near a drop off.

Mow across the slope to slightly uphill.

Mow slopes when the grass is dry and watch for bumps, holes and other obstacles.

Test the slope with the blades off. A good rule of thumb is "Don't mow on • a slope you can't back up".

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

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

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

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

passenger.

prior to operation of the mower. Our aim is to enhance the safe and satisfactory use of this product.

SAFETY Page 2

SAFETY REMINDERS: READ CAREFULLY BEFORE OPERATION

1. Wear appropriate, safe clothing when mowing - close fitting jeans or slacks and heavy 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

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

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

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

9. When the mower is not in use, turn the engine off and remove key. Never leave the engine running unattended. Your Dixon mower is equipped with a weight-sensitive switch that kills the engine when operator leaves the seat while blades are engaged.

"Test this important safety feature before each time mower is used. This may be done by starting engine, engaging blades and then rising slightly from seat. If engine does not stop, see your dealer for necessary repair."

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

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

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

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

A. Use approved gasoline container.

B. Never remove the fuel cap of, or add gasoline to, a running or hot engine, or an engine that has not been allowed to cool after running. Never fill the tank indoors and always clean up spilled gasoline.

C. Never store the mower, with gasoline in the tank, inside the building where fumes may reach an open flame or spark. Allow the engine to cool before storing in any enclosure.

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

15. Never carry passengers.

SAFETY REMINDERS: (continued)

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

A. Use only approved drawbar hitch points.

B. Limit loads to those you can safely control.

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

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

Page 3

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

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

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

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

22. When mowing, proceed as follows:

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

B. Shut the engine off when removing the grass catcher or unclogging chute.

C. Check the blade mounting bolts for proper tightness at frequent intervals.

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

WARRANTY POLICY Page 4

Warranty Policy:

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

Obligation:

Under this warranty policy Dixon Industries, Inc. shall be limited to the replacement to the original purchaser of any part or parts, which, within the warranty period shall be shown to be defective due to faulty workmanship or materials at the factory.

What is NOT covered by Dixon Industries, Inc.:

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

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

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

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

5. TIRES: Warranty extended by tire manufacturer.

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

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

Who is authorized to perform warranty service?

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

Product updates or improvements:

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

Page 5

SPECIFICATIONS

Chassis: 11 GA - rectangular tube.

Body: Two piece - made of DR acrylic reinforced with fiberglass, color fast, scratch and impact resistant. Front body contains access panels for battery service and engine to mower deck belt removal. Rear body tilts up to allow service on the entire drive system.

Seat: Ergonomically designed for operator comfort by use of high density closed cell foam, contoured back rest and arm rests. Seat is adjustable fore and aft.

Mower Deck: 12 GA stamped steel construction, (3) blades, 50" cut width, cut height 1" aides discharge of grass.

Blade Drive: Warner electric clutch.

Drive System: {2} Sundstrand BDU - 10 L hydrostatic transmissions driven by a permanently lubricated peerless gear box.

Engine: 18 HP Briggs and Stratton twin cylinder 1C with cast iron sleeves and ducted air flow.

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

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

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

Hydrostat oil tank - 3 quart with inline 10 micron filter.

Hydrostat oil recommendation - name brand SAE (10-W-30) motor oil.

Dimensions: Width - 60"

Height - 45"

Length - 72"

Weight - 624 lbs.

NOTE: Additional information provided in service instruction under the individual component.

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

SET UP AND SERVICE

1. Seat assembly instructions.

2. Upper control lever installation.

3. Mower deck installation.

4. Deck leveling procedure.

5. Final preparation.

Page 6

Page 7

SEAT ASSEMBLY INSTRUCTIONS

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

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

3. Insert the (2) rear studs of the seat slide into the rear holes of the body cover. Firmly hold seat assembly against body cover with one hand while rear body is raised to fully open position. Continue to hold seat against body to prevent damage to seat safety switch wiring.

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

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

Tighten all nuts fully.

Page 8

UPPER CONTROL LEVER INSTALLATION

1. Raise rear body cover to fully open position.

2. Insert left upper control lever on swivel plate.

3. Install fiber washer and jam nut.

;

4. Proper tightness or tension on jam nut is achieved when swing out movement of upper sloppy in movement.

5. Repeat procedure on right side.

MOWER DECK INSTALLATION Page 9

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

2. Install rear hanger rods on lift frame, as shown in the diagram. Slide lift plate on hanger rods, small holes in lift plate will face rear of mower, install bushings and start nylok nuts on each hanger rod until approximately

1/4 inch of threads are exposed.

3. Position mower deck under chassis.

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

5. Using (1) of the deck support rods, insert the rod at the corner of the lift frame and the front of the mower chassis in the groove provided on the lift frame. Pry backwards on the lift frame enough to connect the brake link into the hole on the tab of the lift lever. This will allow for belt installation in step #7.

6. Raise mower deck at the rear and slide (1) of the deck support rods through the mower deck lift plate and the tabs of the mower deck. "Note" A length of

2 x 4 board turned on end and placed under the mower deck for support will make this task easier if the installation is being done by one person, due to the weight of the mower deck.

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

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

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

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

Page 10

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

Front - (40 - 46 lbs. maximum)

Rear - (20 - 24 lbs. maximum)

B. Remove the discharge chute from the mower deck. Rotate or turn each outer blade tip to align with the edge of the deck or side to side.

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

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

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.

FINAL PREPARATION

1. Remove battery from chassis.

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

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

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

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

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

Engine Service:

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

Initial Start and Hydrostat Transmission Check:

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

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

Page 12

OPERATION INSTRUCTIONS

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

Sound judgment by the owner will prevent accidents.

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

PARKING BRAKE:

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

THE HYDROSTATIC DRIVE SYSTEM:

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

LEVER MOVEMENTS:

No shifting or clutching required.

TO GO FORWARD:

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

TO GO BACKWARD:

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

TURNING:

Turning is controlled by moving one drive lever slightly forward or rearward of the other. To turn left, move left lever rearward of right lever. To turn "square corners" move lever of desired direction to neutral. To turn on mower's own axis

(zero radius) reduce speed and move one lever to reverse position and the other to forward position.

BRAKING:

To brake mower, move both levers in direction opposite of travel, release levers to neutral, set parking brake. When stopping on incline, it may be necessary to hold slight pressure on levers in direction opposite of slope until parking brake is set.

GROUND SPEED:

Ground speed (controlled by movement of hand levers) must be carefully controlled for safety and best mowing results. Never operate at high speed in unfamiliar areas or on slopes.

CHOKE CONTROL LEVER:

Used to start a cold engine. (Engine has not been operated for a length of time)

Located on control panel to operators right.

Page 13

OPERATION INSTRUCTIONS (continued)

THROTTLE CONTROL LEVER:

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

MQKER DECK CUT HEIGHT LIFT LEVER:

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

BLADE DRIVE:

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

LIGHT SWITCH:

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

FUSE BLOCK:

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

Page 14

CARE AND MAINTENANCE - MODEL 501

This portion of the Model 501 owners manual deals with normal service items which can be performed by the owner. Please remember that if you are in doubt as to the correct service procedures to be followed, these and other service situations can be handled by a Dixon ZTR

Dealer who is familiar with the service of your mower.

NOTE:

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

MAINTENANCE SCHEDULE:

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

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

1. Drive system chains, belts and controls.

2. Mower deck belts

3. Tire pressures.

4. Hydrostat oil.

5. Tightness of all nuts and bolts.

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

Page 15

CARE AND MAINTENANCE - MODEL 501

MOWER DECK SERVICE: CUTTER BLADE REMOVAL - BELT TENSION.

"CAUTION" The removal of the cutter blades for either sharpening or replacement is best accomplished by removing the deck assembly from the mower. Do not attempt to raise or lift the front of the mower unless proper safety necessary equipment, entrust this task to your dealer.

DECK REMOVAL: grasp lift quadrant lever, with left hand. Move lever to align with the

(5th) hole from the bottom on the quadrant plate. At this time, connect brake link into hole on lift lever. Move lift lever toward lowest cut position and remove belt from the top of center deck hub assembly.

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

3. Reverse procedure to re-install deck assembly.

CUTTER BLADE REMOVAL:

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

2. When re-assembling blades to hub assemblies, fully tighten blade bolts to installation to insure bolt tightness.

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

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

Page 16

CARE AND MAINTENANCE - MODEL 501

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

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

Step 1. Loosen the front and rear mounting bolts of the hydrostat, turn the rear adjustment bolt downward, which will tension the final drive chain to the rear wheel. Chain is correctly tensioned when at a point mid-way between the sprockets chain free play or movement is approximately l/16th of an inch up and down. Re-tighten mounting bolts.

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

Step 3. Repeat above procedures on opposite hydrostat.

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

Step 5. Position parking brake lever in the off or disengaged position. This will allow the belt idler used on the engine to T-box to swing fully and apply tension to the belt. At this time, check that the cable which pulls the idler to a neutral position has approximately 1-1/2 to 2 inches of free play. If adjustment is required, loosen the lock nuts on the cable block and turn cable sleeve in or out to achieve desired measurement. Re-tighten lock nuts. "NOTE" Cable must have the above dimension with parking brake released or drive belt may slip, causing a loss of power.

Step 6. Neutral adjustment must be checked at this time which will require the engine to be started and the parking brake released. Swing upper control levers outward and into neutral slots, start engine, use caution when releasing parking brake as mower may tend to creep or move prior to re-adjustment of neutral settings on each hydrostat. If adjustment is required, loosen lock nuts at each end of the control rods and back off the tension bolt on each spring block. Turn control rod in or out until neutral is obtained on each hydrostat. Re-tighten lock nuts and tension bolts on spring blocks.

Step 7. Stop engine, move levers to drive position. Lightly push each upper control lever forward until a resistance is felt on the lever. At this time, check that the forward lever stops are hitting against stop block. "NOTE: Do not allow levers to travel to completely forward without hitting stop blocks as damage to hydrostats could result. If adjustment is required, loosen lock nut on lever stop and turn bolt in to allow lever to hit the stop before resistance is felt in the hydrostat.

Step 8. Start engine. Drive mower forward and observe driving condition. If mower tends to pull to either side, re-adjust lever stop on fast side to slow that hydrostat down and even out the ground speed. Do not speed up slow side as over stroking of the hydrostat could result in damage to the unit. If upper control levers are slightly off-set after this adjustment, they can be realigned by bending them into alignment.

(1) HYDROSTAT MOUNTING BOLTS

(2) THREADED ADJUSTERS TO TENSION CHAINS

Page 17

(1) ADJUSTMENT POINTS FOR T-BOX BELT TENSION Page 18

(1) Forward lever stop adjustment Page 19

CARE AND MAINTENANCE - MODEL 501 Page 20

LUBRICATION:

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

LOCATIONS: (1) each front wheel caster

SERVICE INTERVALS:

RECOMMENDED GREASE:

Every (50) hours of operation

Name brand wheel bearing or multi-purpose grease

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

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

DRIVE CHAINS: Primary and final drive

RECOMMENDED LUBRICANT: Name brand aerosol chain spray

SERVICE INTERVALS: As required for operating conditions

Remove excess dirt from chains, lubricate each chain completely by applying the lube to the inside of each connecting link. Applying lube directly to the top of the chain will only allow the lube to be thrown off in operation. The chains are of special construction which use o-rings to seal a factory lubricant inside of the chain.

Additional lubrication will cushion chain to sprocket engagement. Avoid the use of any lubricants which may damage the o-rings used on this chain.

ENGINE OIL CHANGES:

OIL RECOMMENDATIONS:

SERVICE INTERVALS:

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

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

CLEANING THE MOWER:

CARE AND MAINTENANCE - MODEL 501

Page 21

A clean machine 1s a source of pride to the owner. However, cleaning by use of high pressure commercial washes is not recommended. The high water pressure, combined with solvents or alkaline detergents, can lead to corrosion of electrical components or damage to the sealed bearings used on your mower. A better approach is the use of mild household soaps and low water pressure. A stiff brush can be used to loosen excess grass and dirt build up. Avoid directing water pressure onto the mower deck hub assemblies, electrical wiring and engine components such as air filter openings. Never wash or clean the Sundstrand BDO 10 L hydrostatic transmissions, as damage to these units could result. To remove excess water which accumulates during washing of the mower either blow off with compressed air, if available, or start the engine, allowing a long enough operation time to dry thoroughly. It is advisable to engage the mower deck for a short time to disperse all water from pulleys and belts.

Please help protect the environment by avoiding all chemicals which may damage or cause harm to plants and animals in your area.

TROUBLE SHOOTING

Page 22

MOWER CUT QUALITY:

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

The Trouble Shooting Chart suggests practices and adjustments that may be helpful in improving cut quality. Your Dixon ZTR Dealer is also available to provide assistance to you.

SITUATION CAUSES REMEDY

Poor cut quality Ground speed Reduce mowing speed

Poor cut quality Loose belts Adjust per operators

manual

Poor cut quality Engine RPM too low Increase engine RPM to

Poor cut quality Dull or bent blades Sharpen or replace as

required

Poor cut quality Unlevel mower deck Adjust per operators

manual

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

Mower deck mower deck

Poor cut quality Improper blades Replace with original equipment blades which are designed for the Model 501

Poor cut quality Uneven tire pressures Check and adjust as required per operators manual

DRIVE SYSTEM:

SITUATION

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

Oil leaks

TROUBLE SHOOTING Page 23

CAUSES

Drive adjustment

T-Box belts slipping

Belt from engine to

T-Box is slipping

Operation of mower

Loose or missing hose clamps

REMEDY

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

Review operators section of owners manual

Tighten or replace as required

Page 24

ELECTRICAL SYSTEM:

SITUATION

Starter will not turn engine over

Starter will not turn engine over

Battery discharge

Battery discharge

Battery discharge

Electric clutch will not engage mower deck blades

Head lights do not operate

TROUBLE SHOOTING

CAUSE

Blown fuse

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

Low battery condition

Poor connections on clutch switch

Broken wiring

Poor connection, on lights

Broken wiring Bad bulb

REMEDY

Inspect and replace fuse

If fuse continues to burn consult your dealer for repair

Charge battery

Tighten or replace as required

Have electrical system checked by your dealer

Increase engine RPM

Consult your dealer for information

Repair or replace as required

Consult your dealer for repair

Repair or replace as required

Note: obvious first and then move onto the more complicated parts used. Poor battery service, loose connections, corrosion, frayed or broken wiring, are more likely than component failure.

Illustration – Mower Deck Assembly 50” (Model 501)

Illustration — Body Assembly (Model 501)

Illustration – Transmission Assembly (Model 501)

Illustration —Chassis Assembly (Model 501)

3106

3107

3118

3133

3134

3145

3151

3161

3163

3169

3174

3072

3074

3081

3082

3087

3088

3090

3091

3093

3101

3037

3047

3048

3052

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3065

3066

3006

3007

3008

3009

3014

3019

3020

3023

3029

3031

3033

3035

ZTR 501 - PARTS LIST

PART# DESCRIPTION

1657

1668

1675

Spring - Belt Idler

Drive Pulley

Clutch Anchor

1682

1701

1702

1712

1714

1715

1732

1733

1734

1739

1742

1743

1744

1745

2128

2414

2460

2823

3005

L-Rod

Wheel/Deck Hub Bearing

Locking Collar

Battery Strap

T-Box Drive Belt

Rear Wheel & Tire

Pulley - T-Box

Pulley - T-Box Drive

Pulley Hydrostat

Hydrostat Idler Bracket

Bumper

Hydrostat Flat Idler Pulley HO

Hydrostat Drive Belt

Pulley

Sleeve

Spring

Parking Brake Decal

Oil Drain Assembly

5/16"-18 UNC Hex Nut

5/16"-18 x 1 1/4" HH Bolt Gr 5

1/4"-20 UNC Hex Nut

1/4" ID x 3/4" 00 Flat Washer

5/16"-18 UNC x 1 3/4" HH Bolt Gr 5 l/4"-20 UNC x 3/4" HH Bolt Gr 5

5/16" Helical Lock Washer

5/16" Std Flat Washer

1/4" Helical Lock Washer

Front Grommet

5/16"-18 UNC Acorn Nut

1/2" SAE Flat Washer

1/2"-13 UNC Hex Jam Lock Nut

3/8"-24 UNF x I 1/4" HH Bolt Gr 5

3/8"-24 UNF Hex Lock Nut

3/8"-16 UNC x 1 i/2" HH Bolt

3/32" Dia x 1" Cotter P1n

3/16" Dia x 1" Roll P1n

5/16" Fender Washer

3/8" Std Flat Washer

5/16"-18 UNC 1 3/4" Soc Set Screw

3/8" Helical Lock Washer

3/16" Std Flat Washer

1/8" x 1 3/4" Hatr Pin Cotter

5/16"-24 UNF Hex Jam Nut

16-32 UNC Hex Nut

16 Lock Washer

5/16"-18 UNC x 3/4" HH Bolt Sr S l/4"-20 x 1" HH Bolt Gr 5 l/4"-20 x 1 1/4" HH Bolt Gr 5 l/4"-20 UNF Hex Lug Nut

5/16"-18 UNC x 1" HH Bolt Gr 5

7/16" Helical Lock Washer

1/4" x 1" Spirol P1n

1/4" x 1 1/2" Spiral Pin

Disc Spring

#8-32 x 1 1/2" TR 3 Screw l/4"-28 x 1/4" Soc Set Screw

#6 Std Flat Washer

16-32 UNC x 1/2" Rd Hd Screw

5/16"-24 UNF LH Thread

1/2" Int Tooth Lock Washer

3/8"-16 x 1" HH Bolt Gr 5 l/2"-13 x 1" HH Bolt

3233

3235

3243

3245

3247

3248

3249

3256

3257

3258

3259

3260

3204

3205

3206

3208

3220

3224

3225

3228

3229

3231

PART# DESCRIPTION

3180 l/4"-2Q Hex Locknut

3182

3184

Flip Lock Bushing

5/l6"-18 x 1 1/4" Pan Hd Phillips Screw

3185

3186

3187

3188

Washer

#12-24 x 3/4" Drill & Tap Screw

#10-32 Hex Nut

#10 Ext Tooth Lock Washer

3193

3194

3195

3196

3198

Washer .43 x 1.38 x .25

Face Nut 5/8"-32

Face Nut l/2"-27

Face Nut 7/16"-28 l/4"-20 Wing Nut w/Nylok

1/4"-20 Hex Nut w/Nylok

5/16"-18 Hex Nut w/Nylok

3/8"-16 Hex Nut w/Nylok

#10-24 Hex Nut w/Nylok

7/16"-20 x 2 3/4" HH Bolt Gr 5

5/8"-18 x 3/4" HH Bolt w/Nylok Gr 5

3/8"-16 x 2 1/4" HH Bolt

5/B"-11 x 6 1/4" Carriage Bolt

Washer

9/16" Std Flatwasher

Battery Hold Down Bolt

#10-24 x 5/8" Phillips Pan Hd Screw

5/16"-18 x 3 1/4" HH Bolt Gr 5

3/8"-16 Thin Profile Nylok Nut

#6-20 x 1/2" Phillips Pan Hd Screw

5/16" ID x 1/8" Thick Washer

5/8" Int Tooth Lock Washer

Snap Ring

7/16" Int Tooth Lock Washer

5/16"-18 x 4 1/2" HH Bolt Gr 8

5/16"-18 x 5" HH Bolt Gr 8

1/4”-20 x 1/2" HH Bolt Gr 5

3585

3589

3590

3599

3600

3601

3602

3603

3617

3635

3644

3262

3263

3264

3265

3266

3267

3268

3269

3270

3271

3/4”-10 Thin Profile Nylok Nut

5/8”--11 Thin Profile Nylok Nut

5/I6" Disc Spring HD

#10-24 x 3/4" Truss Hd Phillips Screw

1/4” Int Tooth Lockwasher (Not Shown)

5/16"-18 x 1 3/8" HH Bolt Gr 5

3/8"-24 x 1 1/4" HH Bolt Gr 8 w/Nylok

5/16"-18 x 1" Soc HB

5/16"-18 x 3" Soc HB

1"-14 Thin Profile Nylok Nut

3300

3511

3521

Foam Pad

Adhesive Bumper Pad

Engaging Cam Mount Bushing

3531 Decal - OPERATING INSTRUCTIONS

3S36 Decal - DANGER

3552

3553

3554

Tank Mount Bracket - Long

Tank Mount Bracket - Short

Fuel Cap/Guage

3558. 2 Gal Tank w/Cap-Gauge

3578 Nylon Bushing

Decal - CUTTING HEIGHT

Spacer (Electic Clutch)

Key 1/4" Sq x 1/2"

Iso Mount Assembly

Rebound Mount

Load Mount

Spacer Tube

Iso Mount Insert

Decal - DIXON

Tee-Fuel Line

Fuel Line 7 1/2"

Page 29

3722

3723

4013

4075

4092

4124

4144

4145

4146

4151

4197

4198

4199

4201

4211

3711

3712

3713

3714

3715

3716

3717

3718

3719

3720

3721

4331

4385

4400

4401

4402

4403

4404

4405

4415

4216

4217

4242

4257

4268

4269

4274

4275

4276

4284

4428

4430

4446

4448

4453

5028

PART# DESCRIPTION

3645

3646

Fuel Line 18"

Fuel Line 20"

3649

3653

3654

3655

3656

Fuel Line Clamp

Floor Pad Left Front

Floor Pad Right Front

Floor Pad Left Rear

Floor Pad Right Rear

3669

3695

3700

3702

3705

3706

3710

Decal - CAUTION

J-Bolt

Model Decal - (501)

Pulley

Velcro Strip - Hook

Velcro Strip - Latch

Handle Grip

Hour Meter

Handle Grip

Foam Tube

End Cap

End Cap

1/4" Hose Clamp

3/8" Hose Clamp

5/8" Hose Clamp

Heat Shield Deflector

"Tie Wrap

Decal - DANGER

Fibre Washer

Decal - RESERVOIR

Wire Tie

10 Amp Fuse

Fuse Holder

Solenoid w/Hardware

Seat Slide w/o Adjuster

Seat Slide w/Adjuster

Nylon Washer

Utility Box Trim

Ignition Switch

Blade Drive Clutch Switch

Light Switch

Switch Key (Used w/4197)

Solenoid Starter Cable

Battery Ground Cable

Battery

Deck Switch

Utility Box

Upper Wiring Loom

Lower Wiring Loom

Choke Cable

Throttle Cable

Headlight Assembly

Relay

Battery Cable

Seat Back

Arm Rest Offset

Arm Rest Bracket Left

Arm Rest Bracket Right

Arm Rest Assembly Left

Arm Rest Assembly Right

Battery Cover w/Velcro

Seat Bottom

Ground Wire (Hour Meter)

Cover - Flex Guard

Cover - Flex Guard

Engine Wire Assembly

Access Cover Assembly

Bearing

ZTR 501 - PARTS LIST

5503

5504

5507

5508

5510

5511

5512

5514

5515

5516

5519

5521

5522

5525

5530

PART# DESCRIPTION

5070 Key 3/16" Sq x 7/8"

5085

5087

5101

5112

Brake Band

Spacer 3/8" x 1/2"

Brake Link

Key-Sq 3/16" x 1 1/2" (Fits 5110)

5170

5189

5500

5501

5502

Spring

Bushing

T-Box

Mount Plate

Mount Shim

T-Box Guide Left

T-Box Guide Right

Brake Plate Bracket Left

Brake Plate Bracket Right

Sprocket 10T

Sprocket 30T

Sprocket 10 T w/Brake Drum

Brake Rod 5/16" x 2 5/8"

Idler Cable

Swivel

Brake Arm Left

Brake Arm Right

Brake Link Right

Brake Link Left

Control Pivot Shaft

5531

5537

5539

5540

5544

5545

5546

5547

5549

5550

5551

5553

5554

5555

5556

Adjustable Collar

Control Arm Bracket

Hydrostat Support Rod

Neutral Adjust Collar

Swivel Bracket Control Lever Left

Swivel Bracket Control Lever Right

Control Rod End Left

Control Rod End Right

Brake Handle

Hydrostat Left

Hydrostat Right

Spacer 1/2" OD x 2 1/2"

Spacer 1/2" OD x 1/4"

Fan Left

Fan Right

5568

5575

5576

5577

5579

5580

5581

5582

5583

5558

5559

Hose Fitting

Hose Fitting

556C Flbow - Male

5561 Adapter - Male (For 3/8" ID Hose)

5562

5563

5564

5565

5566

5567

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

Tee - Cast Iron

Filter Head

Oil Filter

Hose 3/8" x 7"

Hose 3/8" x 13"

5584

5585

5591

5592

5593

5594

Chain - Primary - Short

Shaft 3/4" x 8 1/4"

Spacer

Drive Chain - Secondary

Electric Clutch HO

Jack Shaft Bracket Left

Jack Shaft Bracket Right

Pivot Shaft Bracket

Hose 5/8" x 19"

Hose 1/4" x 14"

Tab

Reservoir Assembly

Control Lever w/Gr1p Left Hand

Control Lever w/Grip Right Hand

Tube

Page 30

9031

9035

9049

9055

9056

9057

9065

9066

9067

9076

9082

9088

9089

9098

9104

8580

8581

8585

8602

8645

8648

8649

8650

8645

9002

9017

9020

9022

9023

9024

9228

9229

9230

9231

9233

9236

9242

9245

9254

9110

9111

9136

9200

9201

9212

9219

9224

9225

9226

6113

8504

8570

8571

8572

8573

8575

8576

8577

ZTR 501 - PASTS LIST

PART# DESCRIPTION

5595

6011

Hose 5/8" x 14"

Mower Deck Bearing

6059

6100

6101

6111

Flat Idler

Outer Shaft Key

Center Shaft Key

Deck Drive Belt

Blade Washer

Seat Slide Spring

Upper Body w/Decals

Lower Body w/Decals

Headlight Bulb

Headlight Bulb Socket

Wheel Hub Assembly

Rear Rim

Rear Tire

Caster Wheel

Caster Tire

Wiring Kit

Hardware Kit (Electric Clutch)

Seat Assembly (501)

Chain Connecting Link

Rotor/Armature Assembly

Clutch Field Assembly

Cap For Reservoir

Frame

Seat Frame

Caster

Caster Axle Bushing

Engine Mount Plate - Fwd

Engine Mount Plate - Rear

Spacer

Lift Frame

Lift Bushing Bracket

Lift Cam Left

Lift Cam Right

Lift Rod

Lift Handle

Lift Shaft

Control Rod

Seat Frame Cable

Seat Frame Pivot Rod

Caster Wheel & Tire

Control Rod Assembly

L-Rod 9/16" x 15 3/16*

Control Panel

Tank Cover

Rear Wheel Hub

Tube

Mower Deck Assembly

Mower Deck Pan

Spring (Belt Tensioner)

Deck Hub

Outer Shaft

Center Shaft

Deck Hub Sub Assembly

Deck Hub Bearing Spacer

Mower Blade

Outer Hub Assembly

Center Hub Assembly

Deck Idler Bracket

Serpentine Blade Drive Belt

Pulley Guard

Deflector

Lift Plate

Page 31