Dixon 5501 Lawn Mower User Manual
Contents
1. Mower deck belts Tire pressures Hydrostat oil Tightness of all nuts and bolts Electric blade clutch air gap setting Refer to Page 16 for details Oak Refer to engine service manual provided with your mower for maintenance schedules and procedures to be used on the engine Page 15 PROCEDURE FOR ELECTRIC CLUTCH ADJUSTMENT Dixon has used two types of electric clutches One type is Borg Warner and the second one is the Ogura Even though these clutches come from different manufacturers the test procedures are the same for both Few people realize that clutches have maintenance procedures to extend the life of the clutch as they wear over time Below is the information to make these maintenance adjustments and also a procedure to check for a faulty coil In the case that the clutch has failed a part the entire clutch must be replaced since there are no parts available A AIR GAP ADJUSTMENT 1 Remove the clutch from the engine This is recommended because it is easier to verify the 2 Locate the three rivet joints which fasten the leaf springs to the 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 rotor2. 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 manner which will allow access to the blade bolts Hold blade from turning while is removed from 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 60 ft 155 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 the Model 5501 is automatically held in proper by springs which push the deck assembly forward and does not require any additional adjustment to be made Both the belt an
3. 995 7 955 30 jquiessy LOSS Z8 8 LIX 2627 WOO H3 Q I8ZF WOOT H3ddn BLHOI OL ur x ms WN 1932 01 er ALTHO come NNN 0 J3 Q3 NOILINGI d LEADS Ly ATING HAADD li 11585 i Boc ABE OL 31 Ned 20 jquiessy 2495 0005 Page 32 1300 1384 1385 1657 1682 1687 1701 1714 1715 1732 1733 1734 1739 1743 1745 1763 1765 1834 1849 1895 2128 2928 2995 3002 3005 3006 3007 3008 3009 3012 3014 3020 3023 3033 3048 3052 3057 3061 3066 3068 3072 3074 3087 3088 3093 ZTR 5501 PARTS LIST Drive Belt Tank Mount Bracket Short Tank Mount Bracket Long Spring Belt Idler L Rod Idler Pulley Wheel Deck Hub Bearing T Box Drive Belt Rear Wheel amp Tire Pulley T Box Pulley T Box Drive Pulley Hydrostat Hydrostat Idler Bracket Hydrostat Flat Idler Pulley HD Pulley Tie Down w Insulator V Belt Seat Strap Seat Spacer Clutch Anchor Sleeve 3 1 6 X1 Key Commercial Decal 5 16 18X21 2 HHBoltGR8 5 16 18UNCHexNut 5 16 18X14 HHBoltGR5 1 4 20 UNC Hex Nut 1 4 ID X 3 4 OD Flat Washer 5 16 18 UNC X 1 3 4 HH Bolt 3 8 16UNCHexNut 1 4 20 UNC X 3 4 HH Bol
4. Disc Spring HD 10 24 X 3 4 Truss Hd Phillips Screw 1 4 Int Tooth Lock Washer 5 16 18 X 1 3 8 HH Bolt 3 8 24 X 1 1 4 HHB w Nylok 5 1 6 18X1 Soc Hd Bolt 5 16 Int Tooth Lock Washer 8 1 8 X 3 8 Phillips Pan HD 1 2 13Thin Profile Nylok Washer 51 5 X 874 X 031 Foam Pad 5 16 18Thin Profile Nylok Page 33 ZTR 5501 PARTS LIST 3318 3319 3321 3322 3325 3326 3331 3334 3337 3338 3339 3342 3343 3344 3347 3349 3351 3352 3356 3359 3360 3361 3362 3364 3368 3369 3370 3373 3374 3375 3391 3403 3531 3536 3558 3578 3585 3600 3601 3602 3603 3635 3649 3653 3654 Page 34 3 8 16X2 1 4 HH Bolt GR3 Idler Shock Mount 5 16 18X8 HHBoltGR8 5 16 18X51 2 HHBoltGR3 3 8 16X31 2 HH Bolt 3 8 16X4 HHBOoItGRS M6 X P1 X 8MM HH Bolt GR8 8 Nylok Nut Retaining Ring M8 X 1 25 P HWH Screw Snap Ring 5 8 Washer 525 X 1 375 X 25 Hub Bolt Drilled Grease Zerk Washer 1 033 X 1 5 X 06 806 Woodruff Key 1 4 20 X 1 2 HWH Tap Screw 3 8 16X1 1 4 HH Bolt GR5 4112 1 4X3 4 Tap Screw 5 16 18 X 3 HH Bolt GR5 Alt Head 5 16 18 X 4 HH Bolt GR5 Alt Head Stud 1 2 13X2 5 16 18X1 Tap Screw Washer Bent 1 4 20 X 3 4 HWH Tap Screw 1 4 20 U Nut 1 4 Square Key X 2 50 6 32X1 2 HWH Slotted 6 32 Hex Nut x Nylok L Rod 3 5 1 8 X 1 1 2 Cotter Pin Bushing Decal Operating Instructions Decal Danger 2 Gallon Tank w Cap Nylon Bushing Deca
5. From neutral position gently pull both drive levers toward you TURNING Turning is controlled by moving one drive lever slightly forward or rearward of the other To turn left move left lever rearward of the right lever To turn square corners move lever of desired direction to neutral To turn on mower s own axis zero radius reduce speed and move one lever to reverse position and the other to forward position Page 13 OPERATION INSTRUCTIONS Continued BRAKING To brake mower move both levers in direction opposite of travel release levers to neutral set parking brake Park only on level surfaces GROUND SPEED Ground speed controlled by movement of hand levers must be carefully controlled for safety and best mowing results Never operate at high speed in unfamiliar areas or on slopes CHOKE CONTROL LEVER Used to start a cold engine Engine has not been operated for a length of time Located on control panel to operators right THROTTLE CONTROL LEVER Controls engine speed slow to maximum Lever should be set to the maximum or wide open setting to insure adequate cooling of the engine and to maintain mower deck blade speed while mowing MOWER DECK CUT HEIGHT LIFT LEVER Controls the cutting height of the mower deck Seven positions of adjustment in which the very top or highest notch is used for transporting the mower in a non mowing situation Located in front of operator on the right side of mower BLADE DRIVE
6. hold seat assembly against body with one hand while body is raised to fully open position Continue to hold seat against body to prevent damage to seat safety switch wiring 16 Install 1 5 16 standard flat washer 3020 1 seat knob 3874 and 1 nylok nut 3205 on each of the front studs extending through body and seat frame and tighten these nuts 17 Install 1 5 16 standard flat washer 3020 and 1 nylok nut 3205 on each of the rear studs Do not fully tighten these nuts thus allowing for easy slide action of seat as provided by knobs on front studs a Page 8 UPPER CONTROL LEVER INSTALLATION 1 Raise rear body cover to fully open position Install flat washer on right hand swivel plate weldment Next install right hand control lever then second flat washer 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 Page 9 OP EY MOWER 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 s
7. 2 9264 9265 9274 9280 9298 9309 9310 9312 9315 9323 9337 9338 9362 9366 9372 9377 9405 9411 9618 9623 9624 9634 9646 9655 Spring Belt Tensioner Deck Hub Deck Hub Bearing Spacer Pulley Guard Deflector Folding Hi Lift Blade 50 Mower Deck Assembly Engine Plate Caster Tube Assembly Caster Axle LH Caster Axle RH Bumper Weldment Caster Wheel amp Tire Deflector Mount Plate Shaft Tapped Short Shaft Tapped Long Idler Assembly 9276 Deck Baffle Body Brace Brake Lever Deflector Mount Bracket Seat Frame Weldment Lift Handle Weldment Lift Cam Drilled RH Lift Cam Drilled LH Lift Frame Weldment Lift Plate Lift Shaft Weldment NOTES Page 37 NOTES Page 38 DIXON INDUSTRIES INC A BLOUNT COMPANY AIRPORT INDUSTRIAL PARK PO BOX 1569 COFFEYYILLE KS 67337 0945 316 251 2000 FAX 316 251 4117
8. 4 20PHILUPSMACHINESCREW HARDWARE 0914 5 l6SAEWASHER PACKAGE 1 4 14 5 8 WOODSCREW Up 4256 BOX 12 4 3008 1 4 4 OD FLAT WASHER 1314 3356 12 14x3 4 DR amp TAPSCREW EY UL 8414 SEATBOTIOM FRAME Page 7 SEAT ASSEMBLY INSTRUCTIONS ofe pex DD 1812 339 8716 18 x3 HAB ALLTHREAD Cw s _ 326 6 16 18 HEX NUT W NYLOK __ 4 56 18 V TAPPINGSCREW Ez suo 5716 51D FLATWASHER U UU bo NM 12 Install all thread hex head bolts into seat straps Place 1 5 16 18 x 3 bolt through hole located 1 5 8 from end of strap Place 1 5 1 6 1 8 x 4 bolt through hole located 2 7 8 from opposite end of strap Secure each bolt to strap using 1 1 8 SEAT BOTTO thick washer and 1 5 16 18 hex nut w nylok See TURNED UPSIDE DOWN illustration Repeat procedure for other seat strap 13 Attach seat straps to seat bottom as illustrated The 3 stud protruding through strap must be located near the rear of seat while the 4 stud should be nearest the front edge of seat Align remaining seat strap holes with holes in bottom of seat as shown and attach seat straps using 4 5 1 6 18 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
9. CTS 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 9 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 Pickup 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 f There is no other express warranty Implied warranties including those of merchantability and fitne
10. Caster Tire 50 Caster Rim 50 Caster Bearing 50 Bearing Retainer 50 5501 Frame Assembly Upper Body Lower Body w Decals Wiring Kit 3 8 Black Hose 3 75 Oil Valve Hose Assembly Axle Housing Assembly Hydro Mount Housing Splined Reduction Gear Final Drive Gear Axle Assembly Ball Bearing Brake Shaft Page 35 ZTR 5501 PARTS LIST 8439 8440 8441 8442 8443 8444 8452 8460 8467 8468 8469 8470 8471 8472 8572 8573 89 6 8577 8689 8 88 8 91 8893 8854 8855 9023 9031 9049 9067 9082 9098 9110 9156 9157 9158 9159 9164 9165 9168 9171 9172 9174 9175 9191 9192 9196 36 E Ring Ball 3 8 Diameter Bolt 1 2 20 X 2 1 2 Washer 62 X 1 0 X 05 Spring Pin 3 1 6 X 1 2 Type O Grease Tube 42750 Battery Cover Deck Replacement 9273 Ball Bearing Flanged Bearing Brake Pin Lug Bolt Cap Plug 3 8 Cap Plug 1 4 Headlight Bulb Headlight Bulb Socket Rear Rim Rear Tire Mower Blade 50 Standard Tie Bar Anchor Kit Convuluted Loom 1 2 X 60 Fuel Line 22 5 Fuel Line 6 3 8 Hose 26 5 Engine Mount Plate Forward Spacer Lift Bushing Bracket Control Rod Seat Frame Pivot Rod L Rod 9 1 6 X 153 16 Tank Cover Right Swivel Plate Left Swivel Plate Control Lever w Grip Left Control Lever w Grip Right Brake Plate Brake Plate Brake Shaft Weldment Spacer 1 75 Spacer 1 50 Brake Rod Spring Anchor Connecting Link Tie Bar Plate 9212 9219 9228 924
11. DIXON 5501 OPERATORS MANUAL IMPORTANT READ CAREFULLY The Dixon ZTR Mower is both easy and fun to operate However any power mower must be operated properly to be safe It is not a toy or a recreational vehicle Before you start to use the mower read the operator s manual carefully and become completely familiar with the controls The information in this operator s manual applies to all Dixon ZTR Model 5501 Mowers Your Dixon dealer will gladly provide a check out ride and answer any questions See your dealer for warranty service parts and repairs DIXON INDUSTRIES INC A BLOUNT COMPANY AIRPORT INDUSTRIAL PARK PO BOX 1569 COFFEYVILLE KS 67337 0945 316251 2000 FAX 316 251 4117 OMOANOARPWN gt INDEX SAFE Pages 1 3 WARRANTY POLIC Y En Page 4 SPECIFICATIONS zn ae Page 5 SET UPF AND SERVICE etre it tt rot e ete Pages 6 12 OPERATION INSTRUCTIONS Pages 13 14 CARE AND MAINTENANCE Pages 15 22 TROUBLESHOOTING sans nenne Pages 23 25 PARIS IEUUS TRATIONS Pages 26 32 PARTO EAST ocean Pages 33 36 SAFETY RIDING LAWNMOWERS IF IMPROPERLY OPERATED CAN CAUSE SERIOUS INJURY The following examples are the most common causes of injury to the operator or bystander 1 BLADE CONTACT The operator or bystander inserts a hand or foot into the discharge chute or und
12. 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 15 by 1 15 amp circuit breaker If circuit breaker engages push to reset If this condition repeats consult dealer for inspection and repair Page 14 CARE AND MAINTENANCE MODEL 5501 This portion of the Model 5501 owners manual deals with normal service items which can be performed by the owner Please remember that if you are in doubt as to the correct service procedures to be followed these and other service situations can be handled by a Dixon ZTR Dealer who is familiar with the service of your mower NOTE Due to the precision nature of the hydrostatic transmissions used on the Model 5501 internal service repairs cannot be recommended Current service requirements will necessitate replacement of an entire hydro unit if failure should occur MAINTENANCE SCHEDULE To insure a long and trouble free service life on all the components used on the Model 5501 a regular and thorough maintenance schedule should be followed As with any type of precision made equipment a certain amount of initial bedding in or seating of the components will take place The following items should be checked after the first 10 hours of operation and on a weekly basis or each 40 hours of use Drive system belts and controls
13. When the mower is not in use turn the engine off and remove key Never leave the engine running unattended Your Dixon mower is equipped with a weight sensitive switch that kills the engine when operator leaves the seat while blades are engaged This important safety feature must be tested prior to each mowing This may be done by starting engine engaging blades and then rising slightly from seat If engine does not stop see your dealer for necessary repair Before adjusting or servicing your mower turn off the engine and let it cool Be sure all moving parts are stopped Never run the 5501 with the body open Never run the engine indoors the fumes are dangerous Before backing your Dixon Mower stop turn around and look Handle gasoline with care it is highly flammable A Use approved gasoline container B Never remove the fuel cap of or add gasoline to a running or hot engine or an engine that has not been allowed to cool after running Never fill the tank 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 Continued 20 21 22 Never lift lawnmower by the body lift only by the frame Never carry passengers Use care when pulling loads or using heavy equipment A Use ONLY approved drawbar hitch points B Limi
14. aise 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 Ibs maximum Rotate or turn each outer blade tip to align with the edge of the deck or side to side 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 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 a base measurement position Additional adjustment may be required to achieve desired cut for the type of gras
15. and as shown armature faces figure 3 figure 1 6 Tighten the adjusting nut adjacent to the window with the feeler gauge inserted until the gauge fits snugly between the rotor and armature The gap should not be so tight that the feeler gauge cannot be reinserted after removal Brakeplate 7 Repeat Steps 5 and 6 at the other two windows 8 Re check the air gap at each window and make minor adjustments as necessary to achieve a consistent 012 inch air gap bolt back to 50 ft Ibs B OHMS TEST 1 Disconnect clutch from mower wiring harness which is located on the right side of the mower frame rem 2 Set the multi meter on RX1 and attach the two leads to two EE wires coming from the electric clutch 224 3 The reading you receive should be between 2 4 to 2 9 OHMS Feeler Gauge Required Field Adapter 4 resistance is outside this range the clutch coil is faulty 5 If the clutch coil is faulty the clutch must be replaced Page 16 armature rivet joints CARE AND MAINTENANCE MODEL 5501 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
16. d 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 5501 CLEANING THE MOWER A clean machine is a source of pride to the owner However cleaning by use of high pressure commercial washes is not recommended The high water pressure combined with solvents or alkaline detergents can lead to corrosion of electrical components or damage to the sealed bearings used on your mower A better approach is the use of the mild household soaps and low water pressure A stiff brush can be used to loosen excess grass and dirt build up Avoid directing water pressure onto the mower deck hub assemblies electrical wiring and engine components such as air
17. d 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 5501 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 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 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 u
18. er 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 15 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 si
19. filter openings To remove excess water which accumulated during washing of the mower either blow off with compressed air if available or start the engine allowing a long enough operation time to dry thoroughly It is advisable to engage the mower deck for a short time to disperse all water from pulleys and belts PLEASE HELP PROTECT THE ENVIRONMENT BY AVOIDING ALL CHEMICALS WHICH MAY DAMAGE OR CAUSE HARM TO PLANTS AND ANIMALS IN YOUR AREA Page 22 MOWER CUT QUALITY TROUBLESHOOTING 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 Poor cut quality Poor cut quality Poor cut quality Poor cut quality Poor cut quality Poor cut quality Poor cut quality Poor cut quality CAUSES Ground speed Loose belts Engine RPM too low Dull or bent blades Unlevel mower deck Grass build up under mower deck Improper blades Uneven tire pressures REMEDY Reduce mowing speed Adjust per operators manual Increase engine RPM to maximum Sharpen or replace as requi
20. hipment 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 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 9 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 T Install front body connect headlight wiring FRONT HANGER REAR HANGER ROD 4 DECK SUPPORT ROD LIFT PLATE BON 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 r
21. l Cutting Height Rebound Mount Load Mount Spacer Tube ISO Mount Insert Tee Fuel Line Fuel Line Clamp Floor Pad Left Front Floor Pad Right Front A gt 3655 3656 3669 3695 3702 3705 3706 3717 3718 3721 3746 3772 3773 3774 3805 3812 3813 3829 3844 3852 3857 3861 3874 3876 3878 3882 3887 3889 3890 3896 3898 3916 3917 3919 3947 3948 3953 3963 3965 4124 4197 4198 4199 4217 4242 Floor Pad Rear Floor Pad Right Rear Decal Caution J Bolt Pulley Velcro Strip Hook Velcro Strip Latch 3 8 Hose Clamp 5 8 Hose Clamp Decal Danger Decal Parking Brake By Pass Keeper LH Rod End RH Rod End Hand Grip Black Ignition Nut Protective Cap Fuel Line 33 Decal Hydro Gear Spring Fuel Line 23 Control Panel 50 Seat Knob 5 1 6 18 Caster Spring Caster Plug Hand Grip Notched Chrome Lug Nut Drive Pulley 1 13 Bore Bearing Hub Cover Clutch Spacer Decal DIXON Bar Sleeve Hour Meter Fuel Cap Flip Lok Bushing Nylon Bushing Model Decal 5501 L Rod 5 5 Solenoid w Hardware Ignition Switch Blade Drive Clutch Switch Light Switch Battery Deck Switch ZTR 5501 PARTS LIST 4256 4274 4276 4384 4453 4568 4584 4585 4589 4598 4645 4715 4757 4774 4781 4782 5070 5085 5087 5170 5189 5257 5283 5500 5501 5502 5503 5504 5515 5522 5525 5530 5531 5537 5540 5550 5551 5554 5558 5559 5560 5561 5562 5563 5564 Utilit
22. on Deck Leveling Final Preparation SEAT ASSEMBLY INSTRUCTIONS 1 Place seat back against frame of seat bottom Align top amp 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 2 Place 1 armrest bracket against seat back aligning mounting holes in bracket and seat back 3 Insert 2 5 16 18 X 5 8 tapping screws through holes in bracket amp frame and start screw threads DO NOT TIGHTEN SECURELY 4 Insert 1 1 4 20 X 3 4 Phillips machine screw through remaining hole in bracket and start screw threads DO NOT TIGHTEN SECURELY 5 Repeat steps 2 through 4 for the other armrest 6 Tighten all screws T Align back cover to seat back Secure with 4 14 X 5 8 wood screws and 4 5 16 SAE washers in recesses provided 8 Slide armrest onto mounting bracket pin 9 Insert set screw in rear of armrest securing armrest to mounting bracket 10 Repeat steps 8 amp 9 for other armrest 11 Center utility box on seat back cover and fasten with drill amp tap screws and washers provided in separate hardware package E SWUNG UPPER OF IM USE 5 5 DESCRIPTION 1 1 LETBRACKT 2 1 8407 RIGHT BRACKET 8409 BACKCOVR _______ _5 1 8410 SEATBACK _________ 612 3 8 16 3 4 SETSCREW 7 4 S 1 amp BHEXHEADTAPSCREW 8411 816 1
23. ons 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 20 HP Kohler Magnum Vertical Crankshaft 4 Cycle Air Cooled Gasoline Twin Cylinder Opposed Aluminum Crankcase Removable Cast Iron Cylinder Barrels Electronic Ignition Full Pressure Lubrication Electric by key switch operation with safety interlocks on parking brake and blade drive clutch Front 11 X 4 10 X 5 smooth profile Rear 20 X 1 0 X 8 turf savers Fuel 4 8 gallons total dual tanks Hydrostat oil tank 3 quart with inline 10 micron filter Hydrostat oil recommendation name brand SAE 10W 30 motor oil Width 60 Height 45 Length 72 Weight 668 lbs Additional information provided in service instructions under the individual component SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE PageS Page 6 SET UP AND SERVICE 1 Seat Assembly Instructions 2 Upper Control Lever Installation 3 Mower Deck Installati
24. plish 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 A Page 12 OPERATION INSTRUCTIONS The safe and successful operation of the Model 5501 will depend upon the operator having the correct knowledge of all controls used on the mower and making good judgements about the terrain to be mowed NEVER allow anyone to operate the mower without complete knowledge of all controls and their functions Sound judgement by the owner will prevent accidents All controls are described from operators position PARKING BRAKE The parking brake used on the Model 5501 is designed to hold the mower from moving and is not intended for use in stopping the mower while it is in motion An additional safety feature of the parking brake is that the engine cannot be started unless the brake is applied HYDROSTATIC DRIVE SYSTEM Allows the mower to turn on its own axis zero radius Each lever controls one side of the mower The pressure required to operate the mower 15 very light and a minimum of 1 2 hour should be spent simply driving the mower in a non mowing application to gain the confidence necessary to mow like a pro LEVER MOVEMENTS No shifting or clutching required TO GO FORWARD Release parking brake From neutral position gently push both drive levers forward to increase speed move levers farther forward TO GO BACKWARD
25. pper 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 15 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 Page 20 CARE AND MAINTENANCE MODEL 5501 LUBRICATION CHASSIS AND MOWER DECK Number of grease zerks use
26. red Adjust per operators manual Clean out underside of mower deck Replace with original equipment blades which are designed for the Model 5501 Check and adjust as required per operators manual Page 23 TROUBLESHOOTING DRIVE SYSTEM SITUATION CAUSES REMEDY Mower pulls to one Drive adjustment Adjust per operators manual side or the other Consult your dealer for repair Loss of drive power T Box belts slipping Adjust per operators manual on one side or the Consult your dealer for repair other Loss of power on both Belt from engine to Adjust per operators manual wheels after being T Box is slipping Consult your dealer for repair operated for a length of time Poor driving Operation of mower Review operators section performance of owners manual Oil leaks Loose or missing Tighten or replace as required hose clamps TA gt 24 TROUBLESHOOTING ELECTRICAL SYSTEM SITUATION CAUSES REMEDY Starter will not Circuit breaker engaged Push button to reset Consult turn engine over your dealer for repair Starter will not Dead battery Charge battery turn engine over Battery discharge Poor connections on Tighten or replace as required battery Battery water low Wrong battery installed in mower Battery discharge Engine electrical system Have electrical system checked by not functioning correctly your dealer Battery discharge Engine being operated Increase engine RPM Contact your at too low an RPM dealer for info
27. rmation Electric clutch will Low battery condition Repair or replace as required not engage mower Poor connections on Consult your dealer for repair deck blades clutch switch Broken wiring NOTE Electrical system failures are generally simple in nature always check the obvious first and then move onto the more complicated parts used Poor battery service loose connections corrosion frayed or broken wiring are more likely than component failure Page 25 jquiessy Apog Loss MTHHQZSw IHOSI w3H STYI39 A A008 u3wo1 5878 BOE e w230 4 A008 Edda 039340 685 26 WSSSY 515583 LOSS 9 35 Teas E 2815 AE gt EA ar t555 i gt i MN 1233 122 E BB ER i pu i S Y Ig uu s a 5 Me t sig am 1916 d DOT ores a PLOT gt 6227 158 7443 295 27 28 5501 T Box Gearbox and Hydrostats Assembly 09 rquiessy JAMON LOSS 7226 AIBHNISSV MO3O YSMOW 1059 H21n172 91919313 CDI 131707 6598 015 13170 65898 9181 LJ1 nIH SO2B5 Page 29 jquiessy pue sue pue Loss
28. s or conditions being mowed DECK LEVELING ADJUSTMENT POINTS Page 11 FINAL PREPARATION MOWER DECK DEFLECTOR Remove hair pin cotter P N 3072 from deflector pin P N 6402 remove pin Position deflector P N 9264 on mower deck Reinstall deflector pin and hair pin cotter BATTERY Remove battery from chassis 2 Fill each cell with electrolyte acid to ring at bottom of fill cap 3 Allow battery to sit for 1 0 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 accom
29. ss 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 DATE OF PURCHASE Model _ Owner s Dealership Address Address Owner s Signature Dealer s Signature 00000 SEE DEALER FOR DETAILS Page 4 CHASSIS BODY SEAT MOWER DECK BLADE DRIVE DRIVE SYSTEM ENGINE STARTING SYSTEM TIRES CAPACITIES DIMENSIONS NOTE SPECIFICATIONS 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 12 GA stamped steel construction 3 blades 50 cut width cut height approximately 1 to 4 via 7 position lift handle Electric clutch Each rear wheel is independently driven by a Hydro Gear BDU 10L Series 70 hydrostatic transmission The hydrostatic transmissi
30. t 5 16 Std Flat Washer 1 4 Helical Lock Washer 1 2 SAE Flat Washer 3 8 16UNCX1 1 2 HHBolt 3 32 X 1 Cotter Pin 3 8 Std Flat Washer 5 16 18 UNC 1 3 4 Soc Set Screw 3 16 Std Flat Washer 1 8 X1 Cotter Pin 1 8 X 1 3 4 Hair Pin Cotter 5 16 24UNFHexJamNut 5 16 18 UNC X 3 4 HH Bolt GR5 1 4 20X1 HHBoltGR5 5 16 18 UNC X 1 HH Bolt GR5 3100 3106 3130 3140 3160 3161 3163 3178 3182 3187 3188 3195 3196 3203 3204 3205 3206 3207 3208 3220 3224 3225 3227 3231 3235 3237 3243 3247 3248 3249 3256 3257 3260 3264 3265 3266 3267 3268 3269 3272 3273 3297 3298 3300 3310 7 16 Flat Washer 1 4 X1 Spirol Pin 1 2 Contact Belleville Spring 1 4 ID Disc Spring 5 16 Flat Washer 5 1 6 24UNFLH Thread 1 2 Int Tooth Lock Washer 3 8 16X21 2 HH Bolt GR5 Flip Lock Bushing 10 32 Hex Nut 10 Ext Tooth Lock Washer Face Nut 1 2 27 Face Nut 7 1 6 28 3 8 ID Flat Washer Narrow 1 4 20HexNutw Nylok 5 16 18HexNutw Nylok 3 8 16HexNutw Nylok 1 2 13HexNutw Nylok 10 24 Hex Nut w Nylok 7 16 20 X 2 3 4 HH Bolt 5 16 18 X 1 HH Bolt w Nylok GR5 3 8 16X2 1 4 HH Bolt 5 16 18X2 HH BoltGR5 9 1 6 Std Flat Washer 1 0 24 X 9 8 Phillips Pan HD Screw Eye Bolt 5 1 6 X 6 00 5 16 18X31 4 HHBoltGR5 6 20 X 1 2 Phillips Pan Hd Screw 5 1 6 ID X 1 8 Thick Washer 5 8 Int Tooth Lock Washer Snap Ring 7 16 Int Tooth Lock Washer 1 4 20 X 1 2 HH Bolt GR5 5 16
31. t loads to those you can safely control C Do not turn sharply Use care when backing Watch out for traffic when crossing or near roadways Keep the mower in good operating condition and keep safety devices in place and working Keep all nuts bolts and screws tight to be sure the mower is in safe working condition To reduce fire hazard keep the engine free of grass leaves or excessive grease The mower should be stopped and inspected for damage after striking a foreign object or if it starts vibrating and any damage should be repaired before restarting and operating the mower When mowing proceed as follows Mow only in daylight or in good artificial light Shut the engine off when removing the grass catcher or unclogging chute Check the blade mounting bolts for proper tightness at frequent intervals Never operate the machine when using medication or under the influence of alcohol or drugs Don 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 DEFE
32. tuation 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 This mower is not a toy or a recreational vehicle Never allow children CHILDREN to operate the mower in any manner or to ride as a passenger NOTE The six examples are the most frequently cited injury causing situations Please review all the safety precautions outlined on the following pages prior to operation of the mower Our aim is to enhance the safe and satisfactory use of this product Page 1 SAFETY SAFETY REMINDERS READ CAREFULLY BEFORE OPERATION Note Wear appropriate safe clothing when mowing close fitting jeans or slacks and heavy leather or safety shoes with rough soles Never operate this mower with bare feet or open sandals Do not operate on wet or slippery grass Always mow at the slowest speed that will cut satisfactorily Keep hands and feet away from the blade at all times Keep persons clear of the discharge chute Do not operate mower unless deflector is in place When mowing hills or slopes use extreme caution Reduce speed do not make sudden starts stops or turns Always disengage blades before taking the mower across walks or objects that project above the surface Stay alert for holes rocks and roots in the terrain and other hazards Keep away from drop offs
33. y Box Choke Cable Headlight Assembly Relay Access Cover Assembly Throttle Start Cable Battery Ground Cable Covered Key Circuit Breaker Wire Cover 30 Seat Switch Assembly Seat Assembly 50 Battery Cable Assembly Upper Wiring Loom Lower Wiring Loom Key 3 1 6 Sq X 88 Brake Band Spacer 3 8 X 1 2 Spring Bushing Brake Drum Keyed Link T Box Mount Plate Mount Shim T Box Guide Left T Box Guide Right Idler Cable Brake Link Right Brake Link Left Control Pivot Shaft Adjustable Collar Control Arm Bracket Neutral Adjust Collar Hydrostat Hydrostat Spacer 1 2 OD X 1 4 Hose Fitting Hose Fitting Elbow Male Adapter Male For 3 8 ID Hose Adapter Male For 5 8 ID Hose Tee Cast Iron Filter Head 5565 5585 5595 5602 5624 5625 5627 5628 5632 5633 5635 5636 5641 5643 5644 5645 5663 6075 6100 6101 6111 6168 6260 6395 6402 6406 6744 7034 8177 8178 8179 8180 8383 8384 8385 8387 8393 8429 8432 8433 8434 8435 8436 8437 8438 Oil Filter Tab Hose 5 8 X 14 Hose Guard Spring Tank Cap Gearbox Left Fan Right Fan 3 8 Hose 5 5 8 Hose 2 Reservoir Assembly Brass Ferrule G Box Mount Spacer Input Gear GB Bearing Gearbox Bearing Spacer GB Electric Clutch Engaging Idler Bracket Spacer Outer Shaft Key Center Shaft Key Deck Drive Belt Trash Guard Blade Washer Blow By Baffle 50 Deflector Pin Deflector Spring Spring Belt Keeper
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