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INDEX 1. SAFETY Pages 1 - 3 2. WARRANTY POLICY Page 4 3. SPECIFICATIONS Page 5 4. SET UP AND SERVICE Pages 6-11 5. OPERATION INSTRUCTIONS Pages 12-13 6. CARE AND MAINTENANCE Pages 14 - 21 7. TROUBLE SHOOTING Pages 22 - 24 8. PARTS ILLUSTRATIONS Page 29 9. ELECTRICAL SCHEMATIC Page 30 10. PARTS LIST Pages 31 - 33
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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. See your dealer
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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. RUN-O
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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. Do not operate mower unless
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Page 3 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. 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. To redu
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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. Mower De
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Page 6 SET UP AND SERVICE 1. Seat assembly instructions. 2. Upper control lever installation. 3. Mower deck installation. 4. Deck leveling procedure. 5. Final preparation.
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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 t
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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. Levers
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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.
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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. Inflate ti
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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.
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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. PARKING BRAKE: The parkin
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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. Seven positions of adjustment in which the very top, or highest notch, is used for transporting the m
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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. NOTE: , The disassembly and repair of the Sundstrand BDU 10 L hydrostatic transmissions is best left to a qualified Sundstra
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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
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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 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
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Page 17 (1) HYDROSTAT MOUNTING BOLTS (2) THREADED ADJUSTERS TO TENSION CHAINS
