Dixon ZTR 503 Operator'S Manual Download

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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 HEIGHT

3589

Spacer (Electric Clutch)

3590

Key 1/4" Sq X 1/2"

3600

Rebound Mount

3601

Load Mount

3602

Spacer Tube

3603

ISO Mount Insert

3617

Decal - DIXON

3635

Tee-Fuel Line

3646

Fuel Line 20"

3649

Fuel Line Clamp

3653

Floor Pad Left Front

3654

Floor Pad Right Front

3655

Floor Pad Left Rear

3656

Floor Pad Right Rear

3669

Decal - CAUTION

3675

Fuel Line Clamp

3695

J-Bolt

3702

Pulley

3705

Velcro Strip - Hook

3706

Velcro Strip - Latch

3710

Handle Grip

3711

Hour Meter

3712

Handle Grip

3713

Foam Tube

3715

End Cap

3717

3/8" Hose Clamp

3718

5/8" Hose Clamp

3720

Tie Wrap

3721

Decal - DANGER

3723

Decal - RESERVOIR

3729

Handle Grip

3731

Control Panel

3746

Decal - PARKING BRAKE

3747

Deflector Spring

3772

By-Pass Keeper

3773

Left Rod End

3774

Right Rod End

3797

Fuel Tank - Plastic

3813

Protective Cap

3838

Muffler

3840

1/4" Hose - 21"

3844

Decal - HYDRO GEAR

3847

Ignition Nut

3848

Cap Nut

3852

Spring

3876

Caster Spring

3878

Caster Plug

3887

Chrome Lug Nut

3889

Drive Pulley 1.13 Bore

3890

Bearing

3896

Hub Cover

3897

Decal - DIXON

3898

Clutch Spacer - 503

4013

Wire Tie

4075

15 Amp Fuse

4146

Nylon Washer

4198

Blade Drive Clutch Switch

4199

Light Switch

4201

Switch Key

4217

Battery

4242

Deck Switch

4256

Utility Box, Plastic

4274

Choke Control

4276

Headlight Assembly

4384

Relay

4446

Wire Cover 36"

4453

Access Cover Assembly

4467

Fuse Holder

4582

Battery Cable

4585

Battery Ground Cable

4587

Wire Cover

4589

Covered Key

4594

Wire Cover 14"

4605

Model Decal - 503

4687

Battery Cover Assembly

4701

Michigan Seat 50"

5070

3/16" Sq X .88 Key

5085

Brake Band

5087

Spacer 3/8" X 1/2"

5101

Brake Link

5170

Spring

5189

Bushing

5257

Brake Drum

5283

Link *

5500

T-Box

5501

Mount Plate

5502

Mount Shim

5503

T-Box Guide Left

5504

T-Box Guide Right

5515

Idler Cable

5522

Brake Link Right

5525

Brake Link Left

5530

Control Pivot Shaft

5531

Adjustable BUshing

5537

Control Arm

5540

Control Tube

5550

Hydrostat

5551

Hydrostat

5558

Hose Fitting

5560

Elbow - Male

5561

Adapter - Male (For 3/8" ID Hose)

5562

Adapter - Male (For 5/8" ID Hose)

5563

Tee

5564

Filter Head

5565

Oil Filter

5585

Tab

5595

Hose 5/8" X 14"

5602

Hose Guard Spring

5615

Connector/Elbow Assembly

Page 31

Summary of Contents for ZTR 503

Page 1: ......

Page 2: ...r 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 503 Mowers Your Dixon dealer will gladly provide a check out ride and answer any questions See your dealer for warranty ...

Page 3: ...IFICATIONS 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: ...l 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...

Page 5: ...d with a weight sensitive switch that kills the engine when operator leaves the seat while blades are engaged Note This important safety feature must be tested prior to each mowing 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...

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 siriking a foreign object or if it starts vibrating and any damage should be repaired berore 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...

Page 7: ......

Page 8: ...ox are permanently lubricated using a special grease which completely eliminates the need for any type of maintenance The Sundstrand BDU 10L Series 70 hydrostatic transmissions are serviced with any high quality 10W 30 motor oil The oil is filtered by a 10 micron oil filter Recommended service interval for both oil and filter is after the first 150 hours of operation then after every 400 hours of ...

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: ... 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 ...

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: ... allow 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 1s being done by one person due to the weight of the mower deck 7 Raise front of mower deck an...

Page 13: ...s measurement 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 operato...

Page 14: ...irst 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 ...

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 push 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: ...s used for transporting the mower 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 engi...

Page 17: ... to 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 503 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...

Page 18: ...moved 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: ... 1 FORWARD LEVER STOP ADJUSTMENT Page 18 ...

Page 20: ...nded as damage to seals and bearings could occur Using a hand pressure grease gun lubricate each front caster to allow even distribution of grease within the caster rotate or spin each front wheel caster after 3 pumps of the grease gun Repeat process until the appearance of grease is noted completely around each caster ENGINE OIL CHANGES Refer to separate owners manual furnished by OIL RECOMMENDAT...

Page 21: ...ure A stiff brush can be used to loosen excess grass and dirt build up Avoid directing water pressure onto the mower deck hub assemblies electrical wiring and engine components such as air filter openings To remove excess water which accumulated during washing of the mower either blow off with compressed air if available or start the engine allowing a long enough operation time to dry thoroughly I...

Page 22: ...lable to provide assistance to you Page 21 TROUBLE SHOOTING 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 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 REMEDY Reduce mowing speed Adjust ...

Page 23: ...CAUSES Drive adjustment T Box belts slipping Belt from engine to T Box 1s 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 22 TROU...

Page 24: ...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 replace 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 25: ......

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: ...pring 3145 Washer 170 I D 3161 5 16 24 UNF Nut LH Thread 3163 1 2 Int Tooth Lock Washer 3169 3 8 16 X 1 HH Bolt Gr 5 3175 l 2 13 X 1 1 2 HH Bolt 3178 3 8 16 X 2 1 2 HH Bolt Gr 5 3182 Flip Lock Bushing 3184 5 16 18 X 1 1 4 Pan Hd Phillips Screw 3186 12 14 X 1 Drill Tap Screw 3193 Washer 43 X 1 38 X 25 3195 Face Nut l 2 27 3196 Face Nut 7 16 28 3203 3 8 ID Flat Washer Narrow 3204 l 4 20 Hex Nut w Ny...

Page 32: ...840 1 4 Hose 21 3844 Decal HYDRO GEAR 3847 Ignition Nut 3848 Cap Nut 3852 Spring 3876 Caster Spring 3878 Caster Plug 3887 Chrome Lug Nut 3889 Drive Pulley 1 13 Bore 3890 Bearing 3896 Hub Cover 3897 Decal DIXON 3898 Clutch Spacer 503 4013 Wire Tie 4075 15 Amp Fuse 4146 Nylon Washer 4198 Blade Drive Clutch Switch 4199 Light Switch 4201 Switch Key 4217 Battery 4242 Deck Switch 4256 Utility Box Plasti...

Page 33: ...t Bushing Bracket 9055 Lift Cam Left 9056 Lift Cam Right 9057 Front Lift Rod 9065 Lift Handle 9066 Lift Shaft 9067 Control Rod 9076 Seat Frame Cable 9082 Seat Frame Pivot Rod 9098 Hanger Rod 9110 Tank Cover 9142 Rear Lift Rod 9156 Right Swivel Plate 9157 Left Seivel Plate 9158 Control Lever w Grip Left 9159 Control Lever w Grip Right 9164 Brake Plate 9165 Brake Plate 9168 Brake Shaft 9171 Spacer 1...

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Dixon ZTR 503, Operator'S Manual

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