Dixon ZTR 502 manual

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INDEX 1. SAFETY 2. WARRANTY POLICY 3. SPECIFICATIONS 4. SET UP AND SERVICE 5. OPERATION INSTRUCTIONS 6. CARE AND MAINTENANCE 7. TROUBLE SHOOTING 8. PARTS ILLUSTRATIONS 9. ELECTRICAL SCHEMATIC 10. PARTS LIST Pages 1-3 Page 4 Page 5 Pages 6-11 Pages 12 - 13 Pages 14 - 21 Pages 22 - 24 Page 29 Page 30 Pages 31 - 33[...]

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&apo[...]

SAFETY RIDING LAUNMOVJERS, 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 under the mower deck and into the path of the cutting blade. Never run the mower blades[...]

SAFETY Page 2 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 satis[...]

Page 3 SAFETY REMINDERS: (continued) 16. Use care when pulling loads or using heavy equipment. A. Use onl y 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. 18. Keep the mower in good operating condition, and keep s[...]

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Page 5 SPECIFICATIONS Cha ssis: 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: Economically designed [...]

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 t ighten 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 [...]

Page 8 UPPER CONTROL LEVER INSTALLATION 1. Raise rear body cover to fully open position. 2. Install flat washer on right hand swivel plate weld ment. 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[...]

MOWER DECK INSTALLATION 1. To remove front body from chassis , disconnect headlights and remove acorn hut 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, and start nylok nuts on each hanger rod until approximately 1/4 inch of t[...]

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 rea[...]

Page 11 FINAL PREPARATION 1. Re move 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 reading[...]

Page 12 OPERATION INSTRUCTIONS The safe and successful operation of the Model 502 will depend upon the operator having the correct knowledge of all controls used on the mower a nd 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 judgmen[...]

Page 13 OPERATION INSTRUCTIONS (continued) THROTTLE CONTROL LEVER: Controls engine speed. (Engine should be operated at full throttle when use.d in a m owing application, this will insure adequate cooling of the engine as well as maintaining mower deck blade speed) Located on control panel on operators right. MOWER DECK CUT HEIGHT LIFT LEVER: Contr[...]

Page 14 CARE AND MAINTENANCE - MODEL 502 This portion of the Model 502 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 pr ocedures to be followed, these and other service situations can be handled by a Dixon ZTR Dealer who is familiar with the serv[...]

Page 15 CARE AND MAINTENANCE - MODEL 502 MOWER DECK SERVICE: CUTT ER 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 pro per saf ety equipment is ava[...]

Page 16 CARE AND MAINTENANCE - MODEL 502 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 [...]

(1) HYDROS T AT MOUNTING BOLTS (2) THREADED ADJUSTE RS TO TENSION CHAINS Page 17[...]

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

(1) Forward lever stop adjustment Page 19[...]

Page 20 CARE AND MAINTENANCE - MODEL 502 LUBRICATION: CHASSIS AND MOWER DECK: Number of grease zerks used (2) LOCATIONS: (1) ea ch front wheel caster 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 [...]

Page 21 CARE AND MAINTENANCE - MODEL 502 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 o[...]

MOWER CUT QUALITY: There are many variables that can effect the cut quality of any multi blade mower. Type and condi tion of grass, ground speed, blade speed, and con ditions are some of the variables that interact creating differences in cut quality results. In most cases, a smooth, even cut will be achieved without further adjustment. The Trouble[...]

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 performance Oil leaks CAUSES Drive adjustment T - Box belts slipping Belt from engine to T- Box is slipping Operation of mower Loose or missing hose clamps REME[...]

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 CAUSE Blown fuse Dead battery Poor connections on battery Battery water low Wrong battery installed in mower Engine el ect[...]

DECK ASSEMBLY (MODEL 5O2)[...]

Body Assembly ( Model 502)[...]

T- BOX AND HYDROSTATS ASSEMBLY (MODEL 502)[...]

CHASSIS ASSEMBLY (MODEL 502)[...]

FUEL & HYDRAULICS TANKS & FITTINGS ASSEMBLY (MODEL 502) 1 a 1 C a t[...]

WIRING ASSEMBLY (MODEL 502) > t Q ) •[...]

1300 Belt 36" Mower Drive 1384 Tank Mount Bracket (Short) 1385 Tank Mount Bracket (Long) 1469 LH Slide Angle 1470 RH Slide Angle 1471 Seat Slide 1657 Sprin g - Belt Idler 1668 Drive Pulley 1675 Clutch Anchor 1682 L - Rod 1701 Wheel/Deck Hub Bearing 1714 T- Box Drive Belt 1715 Rear Wheel & Tire 1732 Pulley - T - Box 1733 Pulley - T - Box Dr[...]

1991 ZTR 502 Parts List 3601 Load Mount 3602 Spacer Tube 3603 ISO Mount Insert 3617 Decal - DIXON 3635 Tee - Fuel Line 3644 Fuel Line 5 1/2" 3645 Fuel Line 18" 3646 Fuel Line 20" 3649 Fuel Line Clamp 3653 Floor Pad Left Front 3654 Floor Pad Right Front 3655 Floor Pad Left Rear 3656 Floor Pad Right Rear 3669 Decal - CAUTION 3695 J- Bo[...]

1991ZTR 502 Parts List 5615 Connector/Elbow Assembly 5623 Electric Clutch 5624 Tank Cap 5627 Left Fan 5628 Right Fan 6011 Mower Deck Bearing 6100 Outer Shaft K ey 6101 Center Shaft Key 6111 Deck Drive Belt 6113 Blade Washer 6168 Trash Guard 8171 Frame 502 8174 Upper Body Asm 502 8176 Lower Body Asm 50" 8177 Caster Tire 50" 8178 Caster Rim[...]