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Dixon ZTR 502 Operator's Manual
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Dixon ZTR 502 Operator's Manual

Dixon zero turn riding mower operator's manual
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Summary of Contents for Dixon ZTR 502

  • Page 2 SAFETY WARRANTY POLICY SPECIFICATIONS SET UP AND SERVICE OPERATION INSTRUCTIONS CARE AND MAINTENANCE TROUBLE SHOOTING PARTS ILLUSTRATIONS ELECTRICAL SCHEMATIC PARTS LIST INDEX Pages Page Page Pages Pages Pages Pages Page Page Pages 1 - 3 6 - 1 1 1 2 - 1 3 14 - 21 22 - 24 31 - 33...
  • Page 3 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.

  • Page 4: 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.
  • Page 5 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.

  • Page 6: Safety

    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. 18.

  • Page 8: 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.
  • Page 9 Seat assembly instructions. Upper control lever installation. Mower deck installation. Deck leveling procedure. Final preparation. SET UP AND SERVICE Page 6...
  • Page 10 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.
  • Page 11 UPPER CONTROL LEVER INSTALLATION 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. Push control lever into the neutral slot and install (2) cup washers, (1) flat washer and jam nut.

  • Page 12: Lift Lever

    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 threads are exposed.
  • Page 13 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.
  • Page 14 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.
  • Page 15 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 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.
  • Page 16 OPERATION INSTRUCTIONS (continued) THROTTLE CONTROL LEVER: Controls engine speed. (Engine should be operated at full throttle when use.d 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. MOWER DECK CUT HEIGHT LIFT LEVER: Controls the cutting height of the mower deck.
  • Page 17 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.
  • Page 18 CARE AND MAINTENANCE - MODEL 502 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 equipment is available to support the mower.
  • Page 19 CARE AND MAINTENANCE - MODEL 502 DRIVE SYSTEM ADJUSTMENTS: 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.
  • Page 20 Page 17 (1) HYDROSTAT MOUNTING BOLTS (2) THREADED ADJUSTERS TO TENSION CHAINS...
  • Page 21 Page 18 (1) ADJUSTMENT POINTS FOR T-BOX BELT TENSION...
  • Page 22 Forward lever stop adjustment Page 19...
  • Page 23 CARE AND MAINTENANCE - MODEL 502 LUBRICATION: CHASSIS AND MOWER DECK: LOCATIONS: SERVICE INTERVALS: RECOMMENDED GREASE: CAUTION: 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.
  • Page 24 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 on your mower.
  • Page 25 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...
  • Page 26 DRIVE SYSTEM: SITUATION Mower pulls to one side or the other Loss of drive power on T-Box belts slipping one side or the other Loss of power on both wheels after being operated for a length of time Poor driving performance Oil leaks TROUBLE SHOOTING...
  • Page 27 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 Note: Electrical system failures are generally simple in nature, always check the obvious first and then move onto the more complicated parts used.
  • Page 28 DECK ASSEMBLY (MODEL 5O2)
  • Page 29 Body Assembly (Model 502)
  • Page 30 T-BOX AND HYDROSTATS ASSEMBLY (MODEL 502)
  • Page 31 CHASSIS ASSEMBLY (MODEL 502)
  • Page 32 FUEL & HYDRAULICS TANKS & FITTINGS ASSEMBLY (MODEL 502)
  • Page 33 WIRING ASSEMBLY (MODEL 502) > •...

  • Page 34: Parts List

    1991 ZTR 502 Parts List 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 Spring - Belt Idler 1668 Drive Pulley 1675...

  • Page 35: Oil Filter

    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...

  • Page 36: Parts List

    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 Key 6101 Center Shaft Key 6111 Deck Drive Belt 6113 Blade Washer 6168 Trash Guard 8171 Frame 502 8174...