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Dixon ZTR 503 manual

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Table of contents for the manual

  • Page 1

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  • Page 2

    DIXON INDUSTRIES, INC A BLOUNT COMPANY AIRPORT INDUSTRIAL PARK PO BOX 1569 COFFEYVILLE KS 67337 O945 316 251 2OOO FAX 316 251 4117 IMPORTANT - READ CAREFULLY The Dixon ZTR Mower is both easy and fun to operate. However, any power mower must be ope rated properly to be safe. It is not a toy or a recreational vehicle. Before you start to use the mowe[...]

  • Page 3

    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. PARTS LIST INDEX Pages 1 - 3 Page 4 Page 5 Pages 6 - 11 Pages 12 - 13 Pages 14 - 20 Pages 21 - 23 Pages 24 - 29 Pages 30 - 32[...]

  • Page 4

    SAFETY RIDING LAWNMOWERS, IF IM PROPERLY 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 discharg e chute or under the mower deck and i nto the path of the cutting blade. Never run the mower blad[...]

  • Page 5

    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 w ith bare feet or open sandals. 2. Do not operate on wet or slippery grass. 3. Always mow at the slowest speed that will cut sati[...]

  • Page 6

    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 sa[...]

  • Page 7

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  • Page 8

    Page 5 SPECIFICATIONS Chas sis: 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 [...]

  • 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

    Page 7 SEAT ASSEMBLY INSTRUCTIONS 1. Assemble seat as shown in picture. Do not fully tighten the bolts - , - 'hich secure left and right arm rest brackets to seat bottom until se at 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) rea[...]

  • Page 11

    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 t he neutral slot and install (2) cup washers, (1) flat washer and jam nut. (See Illustration) 4. Tighten jam [...]

  • Page 12

    MOWER DECK INSTALLATION Page 9 1. To remove front body from chassis, disconnect headlights and remove acorn nut 1n middle of body. 2. Install rear hanger rods on 11ft frame, as shown In the diagram. Slide lift plate on hanger rods, small holes 1n 11ft plate will face rear of mower and start nylok nuts on each hanger rod until approximately 1/4 inch[...]

  • Page 13

    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 bot tom 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 re[...]

  • Page 14

    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 f or (10) minutes, re - check acid level and top off any cells that are low. 4. Trickle charge battery using a charger of less than (8) amps until all cells are gassing freely. Hydrometer reading[...]

  • Page 15

    Page 12 OPERATION INSTRUCTIONS The safe and successf ul operation of the Model 503 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 co ntrols and their functions. Sound judgme[...]

  • Page 16

    Page 13 OPERATION INSTRUCTIONS (c ontinued) THROTTLE CONTROL LEVER: Controls engine speed, has positive detent in fully opened position to insure adequate cooling of the engine and maintain mower deck blade speed in a mow ing application. Throttle will automatically return to idle position if not locked into the positive detent located on control p[...]

  • Page 17

    Page 14 CARE AND MAINTENANCE - MODEL 503 This portion of the Model 503 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 handle d by a Dixon ZTR Dealer who is familiar with the serv[...]

  • Page 18

    Page 15 CARE AND MAINTENANCE - MODEL 503 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 th e mower unless proper saf ety equipment is avail[...]

  • Page 19

    (1) FORWARD LEVER STOP ADJUSTMENT Page 18[...]

  • Page 20

    Page. 19 CARE AND MAINTENANCE - MODEL 503 LUBRICATION: CHASSIS AND MOWER DECK: Number of grease zerks used (2) LOCATIONS : (1) each front wheel caster SERVICE INTERVALS: Every (50) hour? of operation RECOMMENDED GREASE: Name brand wheel bearing or multi - purpose grease CAUTION: The use of compressed air pressure greasing methods is not recommended[...]

  • Page 21

    Page 20 CARE AND MAINTENANCE - MODEL 503 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 dete rgents, can lead td corrosion of electrical components or damage to the sealed bearings used [...]

  • Page 22

    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 con ditions 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 [...]

  • Page 23

    Drive System : SITU ATION Mower pulls to one side or the other Loss of drive power on one side or the other Loss of power on both wheels after being operated for a length of time Poor driving performance Oil leaks CAUSES Drive adjustment T - Box belts slipping Belt fro m engine to T - Box 1s slipping Operation of mower Loose or missing hose clamps [...]

  • Page 24

    ELECTRICAL SYSTEM: SITUATION Starter will not turn engine over Starter will not turn engine over Battery discharge Battery dischar ge Battery discharge Electric clutch will not engage mower deck blades Head lights do not operate CAUSE Blown fuse Dead battery Poor connections on battery Battery water low Wrong battery Installed 1n mower Engine elect[...]

  • Page 25

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  • Page 26

    1993 T - Box, Gearbox & Hydrostats Assembly Model ZTR 503[...]

  • Page 27

    1993 Fuel & Hydraulics Tanks & Fittings Assembly Model ZTR 503[...]

  • Page 28

    1993 Mower Deck Assembly Model ZTR 503[...]

  • Page 29

    1993 Chassis Assembly Model ZTR 503[...]

  • Page 30

    1993 Body Assembly Model Zl R 5O3[...]

  • Page 31

    ZTR 503 Parts List 1300 Belt 1384 Tank Mount Bracket (Short) 1385 Tank Mount Bracket (Long) 1469 LH Slide Angle 1470 RH Slide Angle 1471 Seat Slide 1627 3/8" Pipe Elbow 1657 Spring - Belt Idler 1668 Drive Pulley 1675 Clutch Anchor 1682 L - Rod 1701 Wheel/Deck Hub Bearing 1714 T- Box Drive Belt 1715 Rear Wheel & Tire 1732 Pulley - T-Box 173[...]

  • Page 32

    ZTR 503 Parts List 3339 Snap Ring - 5/8" 3343 Hub Bolt - Drilled 3344 Grease Zerk 3347 Washer - 1.033 X 1.5 X .06 3348 5/16 - 18 X 3/4" Tap Screw 3349 #806 Woodruff Key 3403 Bushing 3511 Adhesive Bumper Pad 3521 Engaging Cam Mount Bushing 3531 Decal - OPERATING INSTRUCTIONS 3536 Decal - DANGER 3554 Fuel Cap/Gauge 3585 Decal - CUTTING HEIG[...]

  • Page 33

    ZTR 503 Parts List 5623 Electric Clutch 5624 Tank Cap 5625 Gearbox 5627 Left Fan 5628 Right Fan 5631 3/8" Hose - 21" 5632 3/8" Hose - 5" 5633 5/8 " Hose - 2" 5635 Reservoir Assembly 5636 Brass Ferrule 6075 Engine Idler Spacer 6100 Outer Shaft Key 6101 Center Shaft Key 6111 Deck Drive Belt 6113 Blade Washer 6168 Trash G[...]