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.
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 502 Mowers. Your Dixon dealer will gladly provide a check-out ride, and answer any questions.
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 when there are people nearby. Always turn the engine off when cleaning or working around the mower deck. 2.
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 satisfactorily. 4. Keep hands and feet away from the blade at all times. 5. Keep persons clear of the discharge chute.
SAFETY REMINDERS: (continued) Page 3 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. 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 condition. 20.
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: 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.
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 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.
Page 8 UPPER CONTROL LEVER INSTALLATION 1. Raise rear body cover to fully open position. 2. Install flat washer on right hand swivel plate weldment. Next install right hand control lever, then second flat washer. 3. Push control lever into the neutral slot and install (2) cup washers, (1) flat washer and jam nut. (See Illustration) 4. Tighten jam nut. Proper tightness or tension on jam nut is achieved when swing out movement of upper control levers requires some pressure.
MOWER DECK INSTALLATION Page 9 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. 3. Position mower deck under chassis. 4. Place lift lever in 3rd hole from highest cut, position #5 on quadrant. 5.
Page 10 MOWER DECK LEVELING PROCEDURE Leveling Principals: A. There are a total of (4) threaded adjusters which will control the attitude or pitch of the mower deck. The adjusters have lock nuts on the bottom which can be turned up or down to raise or lower the front and rear of the mower deck. Deck should be level or pitched slightly higher in rear. Leveling the Deck: A. Place the mower on a smooth level surface, check tire pressures to insure the mower has a correct stance.
Page 11 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.
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 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.
Page 13 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 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 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 15 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. If you do not have the necessary equipment, entrust this task to your dealer. DECK REMOVAL: 1. Remove front belt access cover from body.
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 adjustment bolt downward, wheel. Chain is correctly sprockets chain free play down.
Page 17 (1) HYDROSTAT MOUNTING BOLTS (2) THREADED ADJUSTERS TO TENSION CHAINS
(1) ADJUSTMENT POINTS FOR T-BOX BELT TENSION Page 18
(1) Forward lever stop adjustment Page 19
CARE AND MAINTENANCE - MODEL 502 Page 20 LUBRICATION: CHASSIS AND MOWER DECK: LOCATIONS: SERVICE INTERVALS: RECOMMENDED GREASE: Number of grease zerks used (2) (1) each front wheel caster 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.
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 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.
Page 22 TROUBLE SHOOTING 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 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 Shooting Chart suggests practices and adjustments that may be helpful in improving cut quality.
Page 23 TROUBLE SHOOTING DRIVE SYSTEM: SITUATION CAUSES REMEDY Mower pulls to one side or the other Drive adjustment Adjust per operators manual Consult your dealer for repair Loss of drive power on one side or the other T-Box belts slipping Adjust per operators manual Consult your dealer for repair Loss of power on both wheels after being operated for a length of time Belt from engine to T-Box is slipping Adjust per operators manual Consult your dealer for repair Poor driving performance Opera
Page 24 TROUBLE SHOOTING ELECTRICAL SYSTEM: SITUATION CAUSE Blown REMEDY Starter will not turn engine over fuse Inspect and replace fuse If fuse continues to burn consult your dealer for repair Starter will not turn engine over Dead battery Charge battery Battery discharge Poor connections on battery Battery water low Wrong battery installed in mower Tighten or renlace as required Engine electrical system not functioning correctly Have electrical system checked by your dealer Engine being oper
DECK ASSEMBLY (MODEL 5O2)
Body Assembly (Model 502)
T-BOX AND HYDROSTATS ASSEMBLY (MODEL 502)
CHASSIS ASSEMBLY (MODEL 502)
1 a 1 C FUEL & HYDRAULICS TANKS & FITTINGS ASSEMBLY (MODEL 502) a t
> t Q ) • WIRING ASSEMBLY (MODEL 502)
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 1657 1668 1675 1682 1701 1714 1715 1732 1733 1734 1739 1743 1744 1745 1801 2128 2164 2173 2823 3005 3006 3007 3008 3009 3014 3019 3020 3023 3029 3031 3033 Spring - Belt Idler Drive Pulley Clutch Anchor L-Rod Wheel/Deck Hub Bearing T-Box Drive Belt Rear Wheel & Tire Pulley - T-Box Pulley - T-Box Drive Pulley Hydrostat Hydrostat Idler Bracket Hydrostat
Page 32 1991 ZTR 502 Parts List 3601 3602 3603 3617 3635 3644 3645 3646 3649 3653 3654 Load Mount Spacer Tube ISO Mount Insert Decal - DIXON Tee-Fuel Line Fuel Line 5 1/2" Fuel Line 18" Fuel Line 20" Fuel Line Clamp Floor Pad Left Front Floor Pad Right Front 3656 3669 3695 3702 3705 3706 3710 3711 3712 Floor Pad Right Rear Decal - CAUTION J-Bolt Pulley Velcro Strip - Hook Velcro Strip - Latch Handle Grip Hour Meter Handle Grip 3715 3717 3718 End Cap 3/8" Hose Clamp 5/8" Hose Clamp 3721 3723 Decal -
Page 33 1991ZTR 502 Parts List 5615 5623 5624 5627 5628 6011 6100 6101 6111 6113 6168 8171 8174 8176 8177 8178 8179 8180 8188 8328 8329 Connector/Elbow Assembly Electric Clutch Tank Cap Left Fan Right Fan Mower Deck Bearing Outer Shaft Key Center Shaft Key Deck Drive Belt Blade Washer Trash Guard Frame 502 Upper Body Asm 502 Lower Body Asm 50" Caster Tire 50" Caster Rim 50" Caster Bearing 50" Bearing Retainer 50" Wiring Kit 50" Greasable Shaft 9225 Greasable Shaft 9224 8689 Mower Blade 50" Std 9023 902
