Dixon ZTR 502 Operator'S Manual Download | Manualshive

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Summary of Contents for ZTR 502

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Page 2: ...NS 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 1 1 Pages 12 13 Pages 14 21 Pages 22 24 Page 29 Page 30 Pages 31 33 ...

Page 3: ...e 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 for warranty service parts and repairs DIXON INDUSTRIES INC Box 1569 Coffeyville Kansas67337 0945 316 251 2000 Airport Industr...

Page 4: ...ll Mow slopes when the grass is 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 preven...

Page 5: ...ped with a weight sensitive switch that kills the engine when operator leaves the seat while blades are engaged Test this important safety feature before each time mower is used 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 10 Before adjusting or servicing your mower turn off the engine and let it...

Page 6: ... is in safe working condition 20 To reduce fire hazard keep the engine free of grass leaves or excessive grease 21 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 22 When mowing proceed as follows A Mow only in daylight or in good artificial light B Shut the en...

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Page 8: ...discharge of grass Blade Drive Warner electric clutch Drive System 2 Sundstrand BDU 10 L hydrostatic transmissions driven by a permanently lubricated peerless gear box Engine 18 HP Kohler twin cylinder with cast iron cylinder pressure lubrication and mechanical fuel pump Starting System Electric by key switch operation with safety interlocks on parking brake and blade drive clutch Tires Front 11 x...

Page 9: ...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 10: ... 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 Continue to hold seat against body to prevent damage to seat safety switch wiring 4 Install 1 flat washer and 1 nylok nut on 1 of the rear studs extending through body cover and seat frame tighten a few threads to hold seat assembly in place 5 Position seat on f...

Page 11: ...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 12: ...for belt installation in step 7 6 Raise mower deck at the rear and slide 1 of the deck support rods through the mower deck lift plate and the tabs of the mower deck Note A length of 2 x 4 board turned on end and placed under the mower deck for support will make this task easier if the installation is being done by one person due to the weight of the mower deck 7 Raise front of mower deck and slide...

Page 13: ...nt Move to the opposite side and 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 D Rotate or turn both outer blades to align with the deck in a front to rear manner Move to the left rear threaded adjuster left rear is designated from operator position ...

Page 14: ... Engine Service 1 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 by...

Page 15: ...onfidence necessary to mow like a pro LEVER MOVEMENTS No shifting or clutching required TO GO FORWARD Release parking brake From neutral position gently puch both drive levers forward to increase speed move levers farther forward TO GO BACKWARD 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 ...

Page 16: ... in a non mowing situation Located in front of operator on the right side of mower BLADE DRIVE 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 LIGHT SWITCH The headlights are activated by pushing the switch forward Failure to turn off the lights once the engine is stopped will result in rapi...

Page 17: ... accurately perform all service required Due to the precision nature of these transmissions field repairs cannot be recommended MAINTENANCE SCHEDULE To insure a long and trouble free service life on all the components used on the Model 502 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...

Page 18: ...emoved Slide deck from under chassis 3 Reverse procedure to re install deck assembly CUTTER BLADE REMOVAL 1 Carefully place deck assembly in a manner which will allow access to the blade bolts Hold blade from turning while bolt is removed from the center of each hub assembly Caution wear heavy thick gloves when holding onto cutter blade avoid the sharp edge of the blade 2 When re assembling blades...

Page 19: ...k nuts NOTE Cable must have the above dimension with parking brake released or drive belt may slip causing a loss of power Step 6 Neutral adjustment must be checked at this time which will require the engine to be started and the parking brake released Swing upper control levers outward and into neutral slots start engine use caution when releasing parking brake as mower may tend to creep or move ...

Page 20: ... 1 HYDROSTAT MOUNTING BOLTS 2 THREADED ADJUSTERS TO TENSION CHAINS Page 17 ...

Page 21: ... 1 ADJUSTMENT POINTS FOR T BOX BELT TENSION Page 18 ...

Page 22: ... 1 Forward lever stop adjustment Page 19 ...

Page 23: ...each caster DRIVE CHAINS Primary and final drive RECOMMENDED LUBRICANT Name brand aerosol chain spray SERVICE INTERVALS As required for operating conditions Remove excess dirt from chains lubricate each chain completely by applying the lube to the inside of each connecting link Applying lube directly to the top of the chain will only allow the lube to be thrown off in operation The chains are of s...

Page 24: ...nd dirt build up Avoid directing water pressure onto the mower deck hub assemblies electrical wiring and engine components such as air filter openings Never wash or clean the Sundstrand BDU 10 L hydrostatic transmissions as damage to these units could result To remove excess water which accumulates during washing of the mower either blow off with compressed air if available or start the engine all...

Page 25: ...lable 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 Incr...

Page 26: ...CAUSES Drive adjustment T Box belts slipping Belt from engine to T Box is slipping Operation of mower Loose or missing hose clamps REMEDY Adjust per operators manual Consult your dealer for repair Adjust per operators manual Consult your dealer for repair Adjust per operators manual Consult your dealer for repair Review operators section of owners manual Tighten or replace as required Page 23 TROU...

Page 27: ...witch Broken wiring Poor connection on lights Broken wiring Bad bulb REMEDY Inspect and replace fuse If fuse continues to burn consult your dealer for repair Charge battery Tighten or renlace as required Have electrical system checked by your dealer Increase engine RPM Consult your dealer for information Repair or replace as required Consult your dealer for repair Repair or replace as required Not...

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 1 a 1 C a t ...

Page 33: ...WIRING ASSEMBLY MODEL 502 t Q ...

Page 34: ...86 12 24 X 3 4 Drill Tap Screw 3187 10 32 Hex Nut 3188 10 Ext Tooth Lock Washer 3193 Washer 43 X 1 38 X 25 3195 Face Nut l 2 27 3196 Face Nut 7 16 28 3198 l 4 20 Wing Nut w Nylok 3199 5 16 18 X 2 1 4 HH Bolt Gr 5 3204 l 4 20 Hex Nut w Nylok 3205 5 16 18 Hex Nut w Nylok 3206 3 8 16 Hex Nut w Nylok 3207 l 2 13 Hex Nut w Nylok 3208 10 24 Hex Nut w Nylok 3220 7 16 20 X 2 3 4 HH Bolt Gr 5 3224 5 16 18 ...

Page 35: ... 4446 Cover Flex Guard 4453 Access Cover Assembly 4467 Fuse Holder 4568 Throttle 4569 Lower Wiring Loom 4687 Battery Cover Assembly 4701 Michigan Seat 50 4714 Upper Wire Loom 5070 Key 3 16 Sq X 7 8 5085 Brake Band 5087 Spacer 3 8 X 1 2 5101 Brake Link 5112 Key Sq 3 16 X 1 1 2 5170 Spring 5283 Link 5500 T Box 5501 Mount Plate 5502 Mount Shim 5503 T Box Guide Left 5504 T Box Guide Right 5507 Brake P...

Page 36: ...nt Plate Rear 9031 Lift Tube 9035 Lift Frame 9049 Lift Bushing Bracket 9055 Lift Cam Left 9056 Lift Cam Right 9065 Lift Handle 9066 Lift Shaft 9067 Control Rod 9076 Seat Frame Cable 9082 Seat Frame Pivot Rod 9089 Control Rod Assembly 9098 Hanger Rod 9110 Tank Cover 9142 Rear Lift Rod 9156 Right Swivel Plate 9157 Left Swivel Plate 9158 Control Lever w Grip Left 9159 Control Lever w Grip Right 9190 ...

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