Dixon 502 User Manual

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'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 [phone] Airport Industrial Park

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-OVER: This situation occurs when a bystander is run-over or backed over by the
mower. The most frequently cited examples are with small children who wander
into, or are allowed to play, in an area where the mower is being operated.
Never run the mower blades when there are people nearby, especially children.
Young children should be indoors and watched by an adult.
Always look behind you before backing up.

3. TIP-OVER: This occurs when the mower tips over, usually sideways or to the rear.
This situation is due to operation of the mower on steep inclines or near a drop
off.

Mow across the slope to slightly uphill.
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 prevent this from
happening, never remove the safety discharge chute from the mower deck, or
operate the mower when other people are around.

5. FIRES: Most accidents of this type occur during re-fueling of the mower or placing
the mower in a storage situation. The exhaust system and related engine
components operate at very high temperatures which can ignite any fuel spilled
on or near them. Always allow the mower to cool before re-fueling or placing in
storage.

6. OPERATION BY CHILDREN: This mower is not a toy or recreational vehicle.
Never allow children to operate the mower in any manner or to ride as a

passenger.

NOTE: The six examples are the most frequently cited injury causing situations.

Please review all the safety precautions outlined on the following pages
prior to operation of the mower. Our aim is to enhance the safe and
satisfactory use of this product.

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 deflector is

in place.

6. When mowing hills or slopes, use extreme caution. Reduce speed, do not make
sudden starts, stops or turns.

7. Always disengage blades before taking the mower across walks or objects that
project above the surface.

8. Stay alert for holes, rocks and roots in the terrain, and other hazards. Keep away
from drop-offs.

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.

"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 cool. Be
sure all moving parts are stopped. Never run the 502 with the body open.

11. Never run the engine indoors; the fumes are dangerous.

12. Before backing your Dixon Mower; stop, turn around and look.

13. Handle gasoline with care - it is highly flammable.

A. Use approved gasoline container.
B. Never remove the fuel cap of, or add gasoline to, a running or hot engine,

or an engine that has not been allowed to cool after running. Never fill
the tank indoors and always clean up spilled gasoline.

C. Never store the mower, with gasoline in the tank, inside the building where

fumes may reach an open flame or spark. Allow the engine to cool before
storing in any enclosure.

14. Never lift lawnmower by the body; lift only by the frame.

15. Never carry passengers.

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. 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 engine off when removing the grass catcher or unclogging chute.
C. Check the blade mounting bolts for proper tightness at frequent intervals.

D. Never operate the machine when using medication or under the influence of

alcohol or drugs.

SPECIFICATIONS

Page 5

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 Deck: 12 GA stamped steel construction, (3) blades, 50" cut width, cut height 1"

to 4" via 7 position lift handle. Self cleaning design, smoothly curved
front, aides 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 4.10 x 5 smooth tread. Rear 20 x 10 x 8 turf savers.

Capacities: Fuel - 4.8 gallons total (dual tanks) with fuel gauges.

Hydrostat oil tank - 3 quart with inline 10 micron filter.
Hydrostat oil recommendation - name brand SAE (10-W-30) motor oil.

Dimensions: Width - 60" Height -

45" Length - 72"
Weight - 665 lbs.

NOTE: Additional information provided in service instruction under the

individual component.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE........................

SET UP AND SERVICE

Page

6

1. Seat assembly instructions.

2. Upper control lever installation.

3. Mower deck installation.

4. Deck leveling procedure.

5. Final preparation.

Page 7

•

NOTE: HARDWARE FOR CON

TROL LEVER ASSEMBLY

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. 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 front holes and install all remaining washers and nylok nuts.
Tighten all nuts fully.

SEAT ASSEMBLY INSTRUCTIONS

SEAT PACKAGE

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 should not fall to the side or be sloppy in movement.

5. Repeat above procedure on left side.